Method for separating lean beef and fat

ABSTRACT

A method for the separation of fat from meat. The method includes transferring a mixture through a conduit, wherein the mixture comprises lean particles with frozen water, fat particles, and a fluid, allowing the frozen water in the lean particles to thaw as the mixture travels through the conduit, and increases a density of the lean particles, accumulating the lean particles with non-frozen water at a first elevation in the conduit, and accumulating fat particles at a second elevation in the conduit, wherein the first elevation is lower than the second elevation.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.13/490,222, filed Jun. 6, 2012 (now U.S. Pat. No. 9,462,824), whichclaims the benefit of U.S. Provisional Application No. 61/493,876, filedJun. 6, 2011, and which is a continuation-in-part of U.S. applicationSer. No. 13/024,178, filed Feb. 9, 2011, which claims the benefit ofU.S. Provisional Application No. 61/302,802, filed Feb. 9, 2010. Allapplications are fully incorporated herein expressly by reference.

BACKGROUND

During the process of boning a carcass, and particularly a beef carcasssuch as a steer or cow, the tallow and fat often referred to as “trim”is removed. Other “trim” is cut from primal beef portions during theslicing and disassembly process of carcasses that is required duringpreparation of small cuts for human consumption. During these processes,a significant amount of lean beef can be cut from the carcass andcarried away with the fat and/or tallow. Lean beef comprisespredominantly muscle protein, although some amounts of fat and talloware present, while fat and tallow comprise predominantly glycerides offatty acids with connective tissue and collagen and are the predominantconstituents of plant and animal fat. The lean beef content in trim maybe as high as 45% to 50% by weight or higher. Presently, trim has littleuse except for sausage production, or alternatively the fat may berendered.

A need therefore exists to more efficiently separate the lower valuetallow with fat from the higher value lean beef contained in trim and tomore effectively kill, reduce, or completely remove the microbialpathogenic population and to eliminate sources of cross contaminationand recontamination, while also producing a ground beef product ofspecific fat content.

SUMMARY

Disclosed are methods relating to the reduction in the tallow contentand/or the separation of tallow and/or fat from materials, particularlyin foods for human consumption, including fresh, uncooked meats and inparticular beef. Tallow comprises natural proportions of fat, collagen,and connective tissue. Disclosed herein is a method and apparatus forseparating lean matter from fat contained within the lean withoutdestruction of the muscle striations.

In one embodiment, the method includes reducing the temperature of atleast the fat component of the beef to a temperature causingsolidification of the fat and to a brittle condition so that when acrushing action is applied to the temperature-reduced pieces of beef,the crushing force is sufficient to cause fracturing and the substantialdisintegration or fragmentation of the fat matter into small fatparticles or fragments that readily fall away from the lean, but withoutsignificantly damaging the lean matter. The temperature-reduced andcrushed stream of fat and lean particles can then be transferred to avibratory separator, which can separate a portion of the fat particleswhile agitating and shaking the larger lean pieces so as to cause evenmore fat particles to separate from the larger lean pieces. Then, theseparated fat particles and larger lean pieces can be combined with afluid that comprises carbon dioxide and/or water to form carbonic acid.The fat and lean matter with fluid are transferred into to a vessel. Thebeef and the fluid are agitated in the vessel to allow temperatureequilibration above the freezing point of water. The beef comprisesrelative lower amounts of less dense (fat) and higher amounts of moredense (lean) matter, which includes a greater quantity of frozen water.The heavy matter that is predominantly lean beef when at least waterpartially unfreezes, such that its density increases to a value above62.4 lbs per cubic foot and can then settle to the bottom of the fluid,and the light matter that is predominantly tallow and fat can risetoward the surface of the fluid. The separated matter comprisingpredominantly lean beef can be removed from the fluid as a reducedtallow and fat content beef product. The method can be practiced withany material containing fat, not just beef, including plants andanimals.

The fluid can include carbon dioxide and water. When pressurized, thefluid can have a pH of about 3 or higher, or even lower, such that whenthe beef is blended in the fluid for a period of time, any bacteria thatis present at the beef surfaces is either killed or injured.Furthermore, the processing of the beef in a substantially all carbondioxide environment around the beef extends the shelf life of the beefby at least displacing oxygen from contacting the beef surfaces.

A first embodiment is related to a method for dividing a quantity offood such as beef into components of fat and lean; and may also separatebone fragments from the beef. The method includes slicing, dicing,flaking and/or chipping beef into smaller beef pieces and freezing thebeef pieces, with or without bone fragments, by reducing the temperatureto below 29.5° F. In one embodiment, the temperature is low enough tofreeze or partially freeze the water in the beef, and in any event, thetemperature is low enough to cause the density of the beef to decreasedue to the expansion of water when chilled to a certain temperature. Thebeef may be combined with fluid having a temperature above 32° F., in avessel, allowing bone fragments to sink to the bottom of the fluidbefore the temperature of the beef increases to above the freezing pointof water. In any event, the bone fragments may be separated while thedensity of the beef is less or nearly equal to the density of the fluid,such that bone is capable of sinking in the fluid, but, not the beef.After the bone has been separated, the temperature of the beef isallowed to increase, and, with a temperature increase, the density ofthe beef also increases due to the volume contraction, mainly by thawingof water contained in the beef. At this point, the density of the beefincreases greater than the density of the fluid, such that the denserlean particles sink to a lower region but above the bone, while fatparticles can rise to the upper region of the fluid. Thereafter, oncelean (beef) particles sink and fat particles rise in the fluid, therespective particles are collected, resulting in a beef product high inlean, a fat product that can be rendered into tallow, and lean beefsolids, through emulsification, heating, pasteurization, andcentrifugation.

A second embodiment is related to a method for separating fat from leanin beef (meat) by fracturing frozen, size reduced, beef pieces thatcomprise a fat component and a lean component. The method includesproviding a quantity of boneless beef and then slicing, dicing, flakingand/or chipping the boneless beef pieces into smaller beef pieces;chilling the beef pieces, by reducing the temperature to below 29° F.;transferring the size reduced frozen beef pieces to a apparatus andapplying a crushing force across the frozen beef pieces so as tofracture the fat component thereby enabling the fractured fat to detachfrom the lean component of each piece of beef, to which the fat waspreviously attached, to provide small pieces of separated fractured fatand larger pieces of lean wherein all finished pieces of fat and leanare smaller than the frozen pieces of beef prior to applying thecrushing pressure to the beef pieces.

A third embodiment relates to an apparatus for separation of fatparticles, lean particles, and, optionally, bone fragments produced bythe method of the third embodiment. The apparatus includes a first,second, third, fourth, and fifth vessel, wherein the first vessel isconnected to the second and third vessel, wherein the bottoms of thesecond and third vessels are at an elevation higher than the bottom ofthe first vessel and means are provided to seal the second and thirdvessels from the first vessel; the fourth vessel is connected to thefirst vessel so that the bottom of the fourth vessel is lower inelevation than the bottom of the first vessel and means are provided toseal the fourth vessel from the first vessel; the fifth vessel isconnected to the fourth vessel so that the bottom of the fifth vessel islower in elevation than the bottom of the fourth vessel and means areprovided to seal the fifth vessel from the fourth vessel; and means toseal the bottom of the fifth vessel.

In the apparatus of the third embodiment, the bottom of the third vesselis higher in elevation than the bottom of the second vessel. In theapparatus of the fourth embodiment, fat or tallow is collected in thesecond vessel.

In the apparatus of the third embodiment, a mixture of carbon dioxide,fat, lean meat and bone are provided in the third vessel and thenallowed to settle.

In the apparatus of the third embodiment, bones or bone fragments arecollected in the fifth vessel.

In the apparatus of the third embodiment, lean meat is collected in thefourth vessel.

In the apparatus of the third embodiment, carbon dioxide is collected inthe first vessel.

A fourth embodiment relates to a method for the separation of fat frommeat. The method includes providing individual pieces of meat containinglean and fat; subjecting the individual pieces of meat to chilling for atime sufficient to produce a difference in temperature between the fatand lean, wherein the fat is chilled such that the fat is brittle, orfriable and can crumble into finer particles when subjected to apressure or crushing force and the lean is chilled to a highertemperature than the fat and, the lean is able to withstand a similarcrushing force without substantially crumbling into smaller pieces. Atthe described temperatures, the beef pieces are subjected to pressure orcrushing force to separate particles of fat from the individual piecesof beef.

In the method of the fourth embodiment, after subjecting the individualpieces of meat to chilling, the temperature at the surface of the fat is5° F. to 10° F.

In the method of the fourth embodiment, after subjecting the individualpieces of beef to chilling, the temperature at the surface of the leanis 16° F. to about 34° F.

In the method of the fourth embodiment, the time of chilling theindividual pieces of beef is approximately 2 minutes to 3 minutes.

In the method of the fourth embodiment, the method can further comprisetransferring the individual pieces of beef and separated particles offat to a vessel and filling the vessel with a fluid comprising, atleast, water, and allowing the particles of fat to rise in the fluid andallowing the individual pieces of beef to sink in the fluid, followed bycollecting the fat and the individual pieces of beef.

In the method of the fourth embodiment, the method may further compriseallowing bone to sink in the fluid to a lower elevation as compared toan elevation attained by the individual pieces of beef.

In the method of the fourth embodiment, the method may further comprisetransferring the individual pieces of beef and separated particles offat within a conduit filled with a fluid comprising, at least, carbondioxide, and allowing the particles of fat to rise in the fluid andallowing the individual pieces of beef to sink in the fluid while thefluid travels in the conduit, followed by collecting the fat and theindividual pieces of beef.

In the method of the fourth embodiment, the method may further comprisesubjecting the individual pieces of beef to a crushing force produced byintermeshing teeth on rollers or a continuous conveyor belt to separateparticles of fat from the individual pieces of beef.

In the method of the fourth embodiment, the method may further comprise,after separating the particles of fat from the individual pieces ofbeef, combining a measured portion of the fat particles with a measuredportion of the individual pieces of beef to achieve a predetermined fatcontent for the beef.

In the method of the fourth embodiment, the method may further comprisecutting raw beef to a size not exceeding 2 inches in any dimension toproduce the individual pieces of beef of step (a).

In the method of the fourth embodiment, after producing the individualpieces of beef, the pieces are chilled to minimize agglomeration ofpieces into frozen masses comprising a plurality of pieces.

In the method of the fourth embodiment, the individual pieces of beefproduced after separation of the fat will comprise predominantly leanbeef.

In the method of the fourth embodiment, the method may further comprisecontacting the separate particles of fat and individual pieces of beefwith a flowing fluid comprising, at least, water, in a conduit, andallowing frozen water in the individual pieces of beef to thaw andincrease in density which causes the individual pieces of beef to fallin the flowing fluid, while the fat particles are buoyant in the fluid,and collecting the individual pieces of beef in a lower conduit of amanifold and collecting the fat particles in an upper conduit of themanifold.

In the method of the fourth embodiment, the method may further compriseseparating the fluid from the individual pieces of beef and fatparticles, weighing the fat, and combining a portion of the fat with theindividual pieces of beef to produce a beef product of predetermined fatcontent.

In the method of the fourth embodiment, the method may further comprisecentrifuging the individual pieces of beef and fat particles to removethe liquid, weighing the individual pieces of beef in a first conveyorand, weighing the fat particles in a second conveyor.

A fifth embodiment is related to a method for deactivating pathogens inbeef. The method includes transferring beef to a vessel, wherein thevessel includes an enclosed elongated space fitted with a first and asecond piston within the interior of the space at each of two opposingends, and the pistons include a front and back side; charging the vesselwith carbon dioxide; moving the first and second piston in a directiontoward each other so as to reduce the volume of the space and increasethe pressure within the space to create super critical carbon dioxidephase (carbon dioxide above the critical pressure and the criticaltemperature) in the space containing the beef; holding the supercritical pressure of carbon dioxide for a predetermined period of time;after holding the super critical pressure for the predetermined periodof time, moving the first and the second pistons away from each other toreduce the pressure in the space to a subcritical pressure of carbondioxide; holding the subcritical pressure of carbon dioxide for apredetermined period of time; and after holding the subcritical pressureof carbon dioxide, moving the first and second pistons in a directiontoward each other so as to reduce the volume of the space whileexpelling the carbon dioxide from the space in front of the pistons tospaces created at the back of the pistons.

In the method of the fifth embodiment, the front side of the first andthe second piston is fitted with an impeller that rotates as the firstand second pistons move toward each other.

In the method of the fifth embodiment, the vessel includes a centrallongitudinal axis, and the vessel is rotated back and forth on the axiswhile the first and second pistons move toward each other.

In the method of the fifth embodiment, the method may compriseperforming a plurality of super critical carbon dioxide phasesalternating with subcritical carbon dioxide phases before expelling thecarbon dioxide.

In the method of the fifth embodiment, the super critical pressureproduced is 1,500 psi or greater.

In the method of the fifth embodiment, the subcritical pressure producedis 900 psi or less.

A sixth embodiment is related to a method for separating lean from fat.The method includes: (a) transferring a mixture through a conduit,wherein the mixture comprises lean particles with frozen water, fatparticles, and a fluid; (b) allowing the frozen water in the leanparticles to thaw as the mixture travels through the conduit, andincreases a density of the lean particles; (c) accumulating the leanparticles with non-frozen water at a first elevation in the conduit, andaccumulating fat particles at a second elevation in the conduit, whereinthe first elevation is lower than the second elevation.

In the method of the sixth embodiment, the method further comprisestransferring the accumulated lean particles through a conduit branchconnected to the conduit, wherein the accumulated lean particlestransferred in the conduit branch comprise a majority of the leanparticles in the mixture.

In the method of the sixth embodiment, the method further comprisestransferring the accumulated fat particles through a conduit branchconnected to the conduit, wherein the accumulated fat particlestransferred in the second conduit branch comprise a majority of the fatparticles in the mixture.

In the method of the sixth embodiment, the method further comprisestransferring a portion of the mixture through a conduit branch connectedto the conduit, wherein the mixture in the conduit branch comprises agreater percent by weight of fluid than fat and lean.

In the method of the sixth embodiment, the lean particles and the fatparticles in the mixture in the conduit prior to thawing of the frozenwater have a substantially similar density that prevents the leanparticles and the fat particles from accumulating at differentelevations.

In the method of the sixth embodiment, the method further comprisesadding carbonic acid solution to the mixture before step (a).

In the method of the sixth embodiment, the fluid has a temperaturehigher than the freezing point of water.

In the method of the sixth embodiment, the mixture may further comprisebones, and allowing the bones to separate from the mixture before thethawing of water.

In the method of the sixth embodiment, the conduit comprises a verticalsection and a horizontal section, and the bones are separated at a bendfrom the vertical section to the horizontal section.

In the method of the sixth embodiment, the method further comprises,before step (a), applying pressure to pieces of beef comprising both fatmatter and lean matter to produce the lean particles and the fatparticles in the mixture.

In the method of the sixth embodiment, the method further comprises,before applying pressure, chilling the pieces of beef to a temperatureat which the fat matter becomes brittle and can crumble and separatefrom the lean matter upon the application of pressure.

In the method of the sixth embodiment, the method further comprisesemulsifying the accumulated fat particles.

In the method of the sixth embodiment, the method further comprisescollecting the accumulated lean particles and centrifuging the leanparticles to separate fluid.

In the method of the sixth embodiment, the conduit can have an aspectratio defined as the cross-sectional width divided by thecross-sectional height, and the aspect ratio decreases along the lengthof the conduit from a proximal side to a distal side.

A seventh embodiment is related to a method for separating fat from beefpieces, including: (a) chilling beef pieces comprising fat matter andlean matter for a time and at a temperature that results in unevenchilling of surfaces of the fat matter and lean matter, wherein the leanmatter is chilled to a temperature to cause freezing of water in thelean matter, and the surface temperature of the fat matter is lower thanthe surface temperature of the lean matter; and (b) applying pressure tothe beef pieces to break the fat matter from the beef pieces whileleaving the lean matter intact.

In the method of the seventh embodiment, the method may further include,wherein in step (b) the surface temperature of the fat matter is lowerthan the surface temperature of the lean matter by at least 5° F.

In the method of the seventh embodiment, the method may further include,wherein in step (b), the surface temperature of the lean matter is 26°F. or less, and the surface temperature of the fat matter is 5° F. orgreater, and the surface temperature of the fat matter is lower than thesurface temperature of the lean matter.

In the method of the seventh embodiment, the method may further includepassing the beef pieces between a pair of parallel, adjacent, noncontacting, driven rollers, each roller having alternating recesses andprotrusions around the perimeter, wherein the rollers are arranged toposition a recess of one roller opposite to a protrusion of the secondroller, without the rollers being in contact.

An eighth embodiment is related to a method of separating a high vaporpressure fluid from beef, including: (a) in an apparatus comprising avessel, and a piston disposed within the vessel, wherein a space isprovided adjacent to the piston, adding a high vapor pressure fluid withbeef in the space; and (b) moving the piston to compress the space toseparate the fluid from the beef, wherein the fluid is compressed at apressure to prevent evaporation and freezing of the beef.

In the method of the eighth embodiment, the apparatus may comprise asecond piston, wherein the pistons are disposed opposite to each other,and the pistons are moved together to compress the space to separate thefluid from the beef.

In the method of the eighth embodiment, the high vapor pressure fluiddoes not exist as a liquid at 1 atmosphere and 20° C.

In the method of the eighth embodiment, the fluid can be carbon dioxide.

In the method of the eighth embodiment, the apparatus may furthercomprise a space behind the piston, wherein the space adjacent to andbehind the piston are in communication, and the fluid is transferredbehind the piston during compression.

A ninth embodiment is related to a method for producing a beef producthaving a predetermined fat content. The method includes: (a)transferring a mixture through a conduit, wherein the mixture compriseslean particles, fat particles, and a fluid; (b) transferring a firstportion of the mixture having accumulated lean particles through a firstconduit branch connected to the conduit, wherein the portion of themixture transferred in the first conduit branch has a majority of thelean particles in the mixture; (c) transferring a second portion of themixture having accumulated fat particles through a second conduit branchconnected to the conduit, wherein the portion of the mixture transferredin the second conduit branch has a majority of the fat particles in themixture; (d) measuring the first portion of the mixture having theaccumulated lean particles in the first conduit branch and determining acontent of fat in the first portion; (e) comparing the content of fat inthe first portion with a target fat content; and further performing (f1)or (f2); (f1) increasing the massflow of the second portion of themixture through the second conduit branch to decrease the fat content ofthe first portion of the mixture in the first conduit branch; or (f2)decreasing the massflow of the second portion of mixture through thesecond conduit branch to increase the fat content of the first portionof the mixture in the first conduit branch.

In the method of the ninth embodiment, the method may further comprisemeasuring the massflow of the first portion of the mixture anddetermining a density, and correlating the density to the fat content ofthe first portion of the mixture.

In the method of the ninth embodiment, the method may further comprise,reducing the mass flow of the second portion of the mixture flowingthrough the second conduit branch and maintaining a constant mass-flowuntil the fat content of the first portion of the mixture reaches a hightarget value, and then increasing the mass-flow of the second portion ofthe mixture through the second conduit branch and maintaining a constantmassflow until the fat content of the first portion of the mixturereaches a low target value, wherein the high target value and the lowtarget value are not the same.

A tenth embodiment is related to a method for inactivating pathogenspresent on pieces of beef. The method includes: (a) introducing into anapparatus, pieces of beef, and a fluid comprising water and carbondioxide; (b) raising a pressure within the apparatus above a criticalpressure of carbon dioxide without elevating a temperature within theapparatus above a temperature to damage the beef; and holding thepressure and temperature for a selected period of time; (c) reducing thepressure within the apparatus, and increasing a density of the fluid tosuspend and separate the pieces of beef in a suspension to enablesurfaces of the beef to be in contact with low pH fluid to result indeath of pathogenic microorganisms on the surfaces of the beef.

In the method of the tenth embodiment, the method may further compriseadjusting the density of the fluid where the beef becomes buoyant toallow spacing apart of beef.

DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages will becomemore readily appreciated as the same become better understood byreference to the following detailed description, when taken inconjunction with the accompanying drawings, wherein:

FIG. 1 is a flow diagram illustrating a process for the separation offat from lean;

FIG. 2 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIG. 3 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIG. 4 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIG. 5 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIG. 6 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIG. 7 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIG. 8 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIG. 9 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIGS. 9A, 9B, 9C, and 9D are diagrammatical illustrations of crosssections of the apparatus shown in FIG. 9;

FIG. 10 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIG. 11 is a diagrammatical illustration of apparatus for thehomogenization and/or emulsification of fat;

FIG. 12 is a diagrammatical illustration of apparatus for thehomogenization and/or emulsification of fat;

FIG. 13A is a diagrammatical illustration of apparatus for breaking fat;

FIG. 13B is a diagrammatical illustration of apparatus for breaking fat;

FIG. 14 is a diagrammatical illustration of apparatus for producingproduct having a desired fat content;

FIG. 15 is a diagrammatical illustration of apparatus for pathogendeactivation;

FIG. 16 is a diagrammatical illustration of apparatus for the separationof fat from lean;

FIGS. 17A and 17B are diagrammatical illustrations of apparatus for theseparation of fat from lean and for the separation of fluid from leanand fat;

FIGS. 18A and 18B are diagrammatical illustrations of apparatus for theseparation of fat from lean and for the separation of fluid from leanand fat; and

FIGS. 19A and 19B are diagrammatical illustrations of apparatus for theseparation of fat from lean and for the separation of fluid from leanand fat.

DETAILED DESCRIPTION

The term “fat” as used herein can mean fat and tallow when used inreference to animal matter. Throughout the description “beef” may beused as a representative material that can be used in the disclosedmethods. However, it is to be appreciated that the disclosed methods canbe practiced not only on beef, but on any meat, such as from poultry,pork, and seafood.

FIG. 1 illustrates a flow diagram for the processing of animal matterthat is a combination of fat and lean matter. A representative animalmatter may be high fat trim byproduct from beef slaughterhouses. In oneembodiment, the source materials can comprise a combination of what iscommonly known as 50's and 65's boneless beef, or any other suitableboneless beef. However, in other embodiments, the beef may combine boneand cartilage.

The method begins with block 2. In block 2, any animal matter may beused. In one embodiment, the animal matter will be beef, such as highfat content beef trimmings and other low value beef products. From block2, the method enters block 4.

In block 4, pathogen deactivation is performed on the animal matter. Anumber of different pathogen deactivation technologies may be employedin block 4. For example, in some embodiments, any of the pathogendeactivation technologies well known in the art may be used. In otherembodiments, the pathogen deactivation process disclosed herein inassociation with FIG. 15 may be used in block 4. From pathogendeactivation block 4, the method enters block 6.

Block 6 is for dicing and/or cutting the generally larger sections ofanimal matter into smaller pieces. Dicing and/or cutting may be donemanually and/or alternatively, with dicing machines. From block 6, themethod enters block 8.

Block 8 is for chilling the diced animal matter or beef pieces fromblock 6. In one embodiment, liquid carbon dioxide, block 10, may be usedfor chilling in block 8. The chilled animal matter has both fat and leanmatter. The chilling method of block 8 results in differences intemperature between the fat and the lean matter, such that the fat is ata temperature that can be separated from the lean by the application ofpressure and can break free of the lean matter, and the lean is at atemperature that is pliable and does not result in the lean matterbreaking free through the same application of pressure. However, thelean matter is chilled to a temperature at which water within the leanmatter can freeze and expand, thus, reducing the density of such leanmatter particles. For example, in one embodiment, the temperature of thebeef pieces should be not more than 29° F. and preferably not less than0° F. but most preferably about 15° F. to about 24° F. From block 8, themethod enters block 12.

Block 12 is for breaking the fat matter free from the lean matter. Theproduct of block 12 comprises particles essentially being all fat andparticles comprising a majority of lean matter, but, fat may still bepresent in a minority quantity.

From block 12, the method may optionally enter block 14. If performed,block 14 is for separation of the small and large particles of fat.After separation, the small particles, block 16, may be combined withany other lean meat, such as pork or beef, block 18. The combination oflean pork or beef with the small particles of fat can be used to producea product having a desired percentage of fat in block 20. The largerparticles of fat are retained with the lean particles in block 14.

If block 14 is not performed, then, from block 12, the method entersblock 22. Block 22 is for introducing a selected amount of a combinationof both lean particles and fat particles. In one embodiment, a rotaryvalve may be placed at the bottom of a hopper as further describedbelow.

From block 22, the method enters block 30. Before entering block 30, thecontents from block 22 are combined with carbonic acid from block 24. Aseparate carbonic acid generation unit may be provided in block 24. Theamount of carbonic acid is measured using a measuring instrument inblock 26. In one embodiment, the temperature of the carbonic acid fluid(suspension or buoyancy medium) should be not less than about 40° F. andnot greater than about 60° F., but most preferably at about 50° F.,before being mixed with the lean particles and fat particles. Carbonicacid is mixed with the combination of lean particles and fat particlesand the mixture is measured in block 28. The mixture of carbonic acid,beef particles, and fat particles is pumped or may otherwise betransferred under gravity flow to a separation apparatus, block 30.

Block 30 separates, at least, a portion of the mixture that comprisesthe majority of the lean particles and a portion of the mixture thatcomprises the majority of the fat particles. Various embodiments ofapparatus may be used for separation and are described below in furtherdetail. Any one embodiment of a separator disclosed herein may be usedin block 30. In one embodiment, separation block 30 may also separate aportion of the mixture comprising bone with some of the liquid in block34. The liquid may be separated from the bone, and further processed.For example, any liquid containing carbonic acid may undergo processingto recover carbon dioxide.

Separation block 30 results in at least two streams. First, a mixture oflean particles and liquid, block 32, and, second, a mixture of fatparticles and liquid, block 36. It is to be appreciated that smallquantities of fat matter is still present in the lean particles. The fatmatter may be attached to the lean particles, or some of the fatparticles may have been entrained with the lean particles. The fatparticles may also include a small quantity of lean matter, either aslean matter directly attached to fat or as separate lean particles. Theliquid containing lean particles is measured in block 38. The liquidcontaining fat particles is measured in block 40. Such measurements caninclude flow rate and density from which fat content as a weight percentof the total flow may be calculated.

From block 32, the liquid containing lean particles is sent to theliquid separation apparatus, block 42. In block 42, liquid/solidseparation can be carried out via a centrifuge or a sedimentationvessel. However, in another embodiment, a separation vessel with one ortwo opposed pistons is described below in association with FIG. 15. Theliquid containing fat particles, block 36, is sent to liquid separation,block 48. In block 48, liquid is separated, in one embodiment, via acentrifuge, and, in another embodiment, via a sedimentation tank, and,in still another embodiment, with the liquid separation vessel of FIG.15.

If a sedimentation vessel is used as the liquid separator in block 48,then, the liquid from liquid separation, block 42, may be sent to thesedimentation vessel used in block 48. Furthermore, liquid separatedfrom bone in block 34 may also be sent to the sedimentation vessel ofblock 48. From block 48, in one embodiment, the liquid is sent to acarbon dioxide recovery apparatus, block 56. The carbon dioxide recoveryapparatus results in carbon dioxide gas, block 58, and waste water,block 60. The carbon dioxide, block 58, can be sent to a storage vessel(not shown) and recirculated to use throughout the various processes,such as in block 22, or used to create carbonic acid in block 24. Thewaste water, block 60, can be discarded or treated. In anotherembodiment, liquid from liquid separation block 48 and liquid separationblock 42 may be sent directly to waste water block 60.

The essentially liquid free lean particles, block 44, and theessentially liquid free fat particles, block 60, are produced having acontrolled amount of fat, and may be used as such for any purpose. Theessentially liquid free lean particles, block 44, and the essentiallyliquid free fat particles, block 60, are considered herein to be thefirst and second portions, respectively, separated from the mixture offluid, lean particles, and fat particles entering the separation, block30. In one embodiment, after separation of the liquid from the lean andfat, the lean is not produced having a controlled amount of fat. In thatcase, the lean and the fat, blocks 44 and 50 respectively, are weighedon weigh conveyors, 46 and 52, and proportioned according to weight toachieve a combined lean/fat product of desired fat conduct in block 54.For example, each respective conveyor can move at a speed that resultsin a specified proportion of lean to fat. However, in other embodiments,using the measuring instruments, blocks 26, 28, 38, and 40, the amountof liquid with fat that is sent to block 36 can be increased ordecreased, which causes a corresponding decrease or increase of the fatthat is carried with the lean particles to block 32. Thus, the weighconveyors 46 and 52 are optional.

The ability to measure the fat content of beef matter within a fluid isbased on the realization that the density of a fluid with solid mattercorrelates to a fat percentage. The fat content of any beef matter,regardless whether the beef is predominantly lean matter or fat matter,can be determined by knowing the density of the combined fluid and solidmatter. In one embodiment, a correlation table can be created thatcorrelates density with fat percent. The table may be createdempirically after conducting numerous trials. The table may be stored ina storage device, such as computer memory, or databank. In oneembodiment, the instruments that measure density are known as coriolisinstruments. Coriolis measuring instruments, as used herein, are capableof measuring massflow, density and temperature. Instead of using asingle measurement of massflow, an average may be taken of a pluralityof measurements over a time period. Density is determined from massflowby dividing the massflow by a known volume in the instrument.Accordingly, since massflow includes the mass of the fluid and of anysolids, the density is not the density of the fluid or solids, but thedensity of the mixture of fluid with solids. Once the density is known,the fat content can be ascertained through a correlation table. It is tobe appreciated that the fluid has no fat content; thus, the fat contentthat is ascertained refers to the fat content of the solid matter withinthe fluid. Accordingly, once the fluid is separated, the fat contentremains the same.

In FIG. 1, between the rotary valve block 22 and the separation block30, the temperature of the beef matter, including fat and leanparticles, will initially be low enough such that the lean and fatparticles will float (but not the bone matter) in the fluid; however,the temperature and volume of the fluid from block 24 is such that thefrozen water content of the lean will unfreeze and the density willincrease accordingly. Separation of the lean/liquid stream, block 32,from the fat/liquid stream, block 36, in this way results in a leancontent of the lean stream of about 92% and a lean content of the fatstream of about 20%. By dividing the fat stream further into two streamsof almost pure (fatty adipose tissue) and a stream of higher leancontent fat, the almost pure fat stream will comprise at least 12% leanand the higher fat content stream could be about 30% lean.

The massflow of fluid, e.g. carbonic acid, is measured in block 26. Thefluid can be carbonic acid or any other acid or high pH value alkaliliquid, such as ammonium hydroxide. The combined massflow of fluid withbeef matter is also measured in block 28. Therefore, the massflow ofbeef solids, including fat and lean particles, can be known bysubtraction of the measurement of block 26 from the measurement of block28. The massflow of lean/liquid leaving the separation block 30 ismeasured in block 38. Therefore, density of the lean/liquid is known anda correlation table is used to ascertain the fat content. The massflowof fat/liquid leaving the separation block 30 is measured in block 40.Therefore, density of the fat/liquid is known and a correlation table isused to ascertain the fat content.

The massflow of the fat/liquid stream, block 36, is controlled by a pumpthat is controlled with a variable frequency drive electric motor thatcan operate in the following manner. The lean/liquid stream, block 32,is measured to determine a fat content (which may be 8%); then, if thetarget is to produce 85% lean, the fat/liquid stream massflow isrestricted so that more of the fat/liquid stream must flow into thelean/liquid stream to add, say an additional 8% fat, and when this lowertarget value (84% lean) is measured by measuring instrument block 38(based on the density/fat correlation table), the pump is opened toallow more fat to be transferred away from the lean/liquid stream. Whena higher target value, say 86% lean, is measured by the measuringinstrument block 38, the pump is opened so as to add just 6% additionalfat. In this way, a harmonic motion or cycle can be created wherein theupper limit fat content is 16% and the lower limit fat content is 14%and this cycle can be continuously repeated.

The process blocks of FIG. 1 are not limited to being performed in anyparticular sequence. For example, pathogen deactivation may occur afterblocks 42 and 48 or any time before then. Some steps may be omitted andsubstituted for one or more steps, or that perform the similar function,or are arranged in a different sequence to perform the similar function.Some steps may be omitted that are merely ancillary, or embraced as asubsystem of the illustrated steps.

The blocks discussed above will now be described in more detail withreference to specific figures.

1. Blocks 2, 4, 6, 8, 12, and 14

Equipment for performing the process blocks 2 (beef input), 4 (pathogendeactivation), 6 (dicing), 8 (chilling), 10 (liquid carbon dioxide), 12(bond breaking), and 14 (particle separator) of FIG. 1 are morespecifically shown in FIG. 2.

Referring now to FIG. 2, the section shown between item number 1002through item number 1046 represents the beef pathogen deactivation andparticle preparation systems. The pathogen deactivation apparatusidentified as 1022 can be substituted with the high pressure supercritical carbon dioxide pathogen deactivation process described inassociation with FIG. 15.

Equipment 1002 represents a vat dumper which may unload any quantity ofanimal matter containing fat and lean, such as for example, theunloading of containers of approximately 2,000 lb of beef onto aninspection section followed by size reduction equipment 1004. Combodumpers can dump raw beef onto an inclined conveyor which delivers thebeef to size reduction equipment and optionally a cutting table arrangedto provide for manual cutting and reduction in size of beef pieces thatare too large to be processed by the size reduction equipment 1004. Beefmay be boneless or may include bone and cartilage matter as well. Sizereduction equipment 1004 may reduce the beef to pieces of approximatelynot bigger than 12″ in any dimension. The inspected, size reduced beefis them transferred to accumulation hopper 1014 via conveyor 1008. Fromhopper 1014, the beef may be transferred via the application of vacuumthrough conduit 1016 to the pathogen deactivation system 1022. Oneparticular embodiment of a pathogen deactivation system is described inassociation with FIG. 15, which uses carbon dioxide that is then drawnout from pathogen deactivation system 1022 via conduit 1020. In anotherembodiment, an autoclave is used as the pathogen deactivation system.

After treatment to reduce pathogens, the beef is transferred from thepathogen deactivation system 1022 via conduit. 1026 to dicing equipment1028. Transfer of beef at this stage may be via pump 1024. Pump 1024 isdesigned to transfer a continuous substantially void free stream ofpressurized beef within the conduit 1026, which may include a measuringinstrument, such as a mass flow meter or coriolis meter. Coriolis meterscan measure density, mass flow, and temperature of the materialtransferred therethrough. For example, the proportion of water containedin the beef transferred therethrough can be determined and recorded forcomparison with similarly measured beef after processing. The moisturecontent of the beef is recorded, and moisture content throughoutprocessing of the beef can be achieved by measuring the water contentprior to processing, during the process to check on any variation, andafter processing to confirm the “natural” water content of the beef isnot exceeded. The data collected by coriolis measuring instruments isrecorded automatically on computer disc or memory as the beef advancesthroughout the process.

From dicing equipment 1028, beef pieces are transferred on conveyor 1032through a tunnel freezer 1036. Tunnel freezer 1036 may use carbondioxide as the chilling medium. Carbon dioxide is admitted and extractedthrough either of conduits 1034 or 1040 depending on whether thechilling operation is conducted concurrent or countercurrent with theflow of beef. The dicing equipment 1028 is designed to slice and dicethe beef and reduce beef to a particle size preferably about 1 inch incross section by 2 inches or less. While not limiting, the particles aresize reduced to approximately not more than about 1 inch wide and 2inches long strips or 2 inch cubes. The individual particles of dicedbeef may still contain an amount of fat and an amount of lean. The inputtemperature of the beef particles to the tunnel 1036 (block 8 of FIG. 1)may be about 32° F. to 40° F., but preferably about 32° F. Thetemperature of the beef before the tunnel freezer 1036 may becontrolled, in general, by adjusting the temperature of the room inwhich the beef is being diced. Owing to the differences of heat transferbetween fat and lean in each beef piece, and respective amounts of waterin lean versus fat matter, the chilling tunnel 1036 results in differenttemperatures of fat and lean within each beef particle.

It has been realized that the temperature of the individual particlesthat exit the chilling tunnel 1036 is not uniform throughout theparticles. Because of the different heat transfer rates of fat and leanas well as the different percentages of water within lean and fat, thetemperature of the lean will be higher than the temperature of the fat,even of the same particle. The temperature reduction is carried out toresult in lean matter that remains flexible due to the cohesiveproperties of muscle tissue, while the fat is cooler at the surface andis in a brittle and friable condition due to the lower temperature.However, because the lean contains greater amounts of water than fat,the water is frozen or partially frozen.

In one embodiment, flooding the tunnel 1046 enclosure with 100% carbondioxide gas displacing what would otherwise be air is advantageous. Inthis way, carbon dioxide gas can be recycled through the evaporators.Another purpose in the use of carbon dioxide is to displace air (andtherefore atmospheric oxygen), thereby inhibiting the formation ofoxymyoglobin from the deoxymyoglobin exposed at the cut lean surfaces ofeach dice or beef particle when diced or sliced.

The temperature of the quickly frozen beef particles when exiting thetunnel 1036 is controlled such that lean matter comprising substantiallymuscle striations, will freeze the water and all naturally fluids. Waterrepresents about 70% of lean matter and thus the freezing and expansionof water when frozen contributes a significant increase in volume with acorresponding decrease in density of the lean matter. The beef particlesare in a solid phase but in such a way that the physical characteristicsand properties of the lean matter is pliable and “rubbery” in texture,while the fat matter is friable such that it fractures when subjected tocompressive and twisting actions and will crumble readily into smallparticles and be freed from the lean matter. The temperature to whichthe beef particles are reduced needs to alter the physical condition ofthe beef particles so as to facilitate the flexing of the musclestriations of the lean matter without causing it to fracture and breakinto smaller pieces, while simultaneously rendering the fat matterfriable such that it will fracture, crumble, and break into smallerseparate particles. In this way, the friable fat having broken away fromthe lean when it is flexed, crushed, bent, or twisted, thereby reducesthe fat matter into small separated particles. Hence, these are referredto herein as fat particles. The part of the beef pieces remaining arerelatively larger comprising mostly lean matter (because they aregenerally not broken into small particles). Hence, these are referred toherein as lean particles. The change in physical breakdown of the beefparticles into two types of particles is caused by lowering thetemperature thereof followed by physical disruption of the bond, whichfixes the fat and lean matter together in an attached state, and resultsin a size difference between the larger lean particles compared tosmaller fat particles.

It has been found that by reducing the temperature of the beef particleswith fat to a range of between less than 29° F. and above 26° F., theprocess described above will facilitate separation by providing friablefat fractures permitting the fat to crumble into small particles,leaving the lean as larger particles.

The tunnel freezer 1036 may be a cryogenic freezer using nitrogen orcarbon dioxide as the refrigerant, such that upon transfer out of thefreezing tunnel 1036 (or other style of freezer) the temperature of thefat (at its surface) is lower than the temperature of the lean in eachparticle or separate piece of beef. In one embodiment, the beefparticles are temperature reduced by transfer through tunnel freezer1036 such that the surface temperature of the fat matter is lower(approximately 5° F.) than the surface temperature of the lean matter,which is shown to be about 29° F., immediately following discharge fromthe freezer. The temperature at the surface of fat may be at about 5° F.or less and up to 10° F. or more such that it can be friable and crumbleupon application of pressure, while the temperature of the lean may be16° F. to about 34° F., or alternatively below 29° F., which makes thelean flexible and not frozen into a “rock-hard” condition immediatelyafter removal from the freezing process.

The above description of creating friable fat prone to crumble isattributed to the respective differences in the heat transfer ability offat compared to lean. Table 2 shows representative temperatures of fatand lean exiting a tunnel freezer. Referring to TABLE 2, the temperatureof the lean and fat matter is separately plotted against elapsed time.As can be seen, the temperature of the lean matter is above thetemperature of the fat matter for about 5 minutes subsequent todischarge from the freezer and at about 6 minutes (after discharge fromthe freezer) the lean temperature is lower than the fat temperature.

In one embodiment, immediately after leaving the tunnel freezer, the fatcan be at a temperature of 5.2 F. (at the surface), while the lean is ata temperature of 29 F. This difference in temperature is attributed tothe respective heat conductive properties of fat versus lean. Theindividual pieces of beef containing both fat and lean are exposed tothe freezer on the order of minutes, generally, between 2 and 3 minutesto create friable fat matter prone to crumble under a crushing force,whereas the lean remains pliable, flexible and not prone to crumbleunder a similar crushing force. The temperatures will then begin toconverge to equilibrium; therefore, it is useful to process theparticles of beef in the bond breaking compression device 1042 beforethe fat is no longer friable and easy to crumble.

TABLE 2 Temperature Difference of Fat and Lean Temperature Date Timedelta T′ delta T Fat Lean  1 Aug. 3, 2010 3:31:00 PM 0:00 0:00  5.2 29.0 2 3:37:00 PM 0:06 0:06 27.9 26.6  3 3:43:00 PM 0:06 0:12 29.5 26.9  43:50:00 PM 0:07 0:19 30.9 27.8  5 3:58:00 PM 0:08 0:27 29.7 28.6  64:03:00 PM 0:05 0:32 30.6 28.9  7 4:14:00 PM 0:11 0:43 31.0 29.5  84:22:00 PM 0:08 0:51 32.8 29.8  9 4:31:00 PM 0:09 1:00 33.3 30.0 104:36:00 PM 0:05 1:05 35.3 30.0

The stream of temperature reduced beef particles can then beimmediately, without storing in containers or otherwise that could allowtemperature equilibration of the fat and the lean matter, or on anextended conveyor, be transferred through a bond breaking process duringwhich the beef particles are “flexed” or bent by distortion andpartially crushed as they are transferred between, for example, a pair(two) of parallel rollers manufactured from any suitable stainless steelsuch SS316 or SS304 grades, but wherein the beef particles are notcompletely flattened as would occur if placed on a hard surface androlled upon with a very heavy roller (steam/road roller for example).This bond breaking compression process is intended to cause breakage ofthe friable fat matter into smaller pieces of, in the majority ofinstances, approximately 100% fatty adipose tissue (fat) and smallerthan the fat matter was before transfer through the bond breakingprocess and much more so than the lean matter which remains in mostcases intact but without any more than about 10% fat, or less, remainingattached to the majority of lean matter after transfer through the bondbreaking process. In other words, the fat in the beef particles will“crumble”, fracture, and break into small pieces and separate from thelean in a continuous stream of what becomes small (smaller than beforetransfer through the crushing process) fat particles and lean particlesthat still comprise some fat, but are approximately more than 90% leanbeef.

Following temperature reduction in tunnel 1036, and while the fat andlean maintain different temperatures, as discussed above, the beefparticles still containing fat and lean are transferred to a bondbreaking compression device 1042 that clamps and flexes the particles soas to cause the friable fat to crumble and break away from the flexiblelean component of the beef. Device 1042 may comprise at least one ormore pairs of horizontally disposed and opposed specially manufacturedrollers, such as rollers 1043 and 1045, arranged so that one pair isabove the other, such that the stream of beef particles spread outacross the full width of the tunnel conveyer are dropped in a waterfalleffect between the upper pair of rollers which clamp the particles andflex so as they are transferred between the clamping rolls withoutcrushing and in this way cause the friable fat matter attached to anyflexible lean matter to break away in small particles. One embodiment ofa profile of a pair of rollers is described in association with FIGS.13a and 13b . After processing between the upper pair of rollers, thestream of beef particles drops between the second pair of similarlyarranged rollers driven by a suitable electric motor to ensureprocessing of all particles which are then transferred to accumulationhopper 1044 and by vacuum transfer are conveyed via conduit 1046 intohopper 1054 mounted above the inlet to the separation manifold 1072.From the description above, embodiments for separating lean from fat arepossible by chilling, followed by the application of pressure or acrushing.

In one embodiment, a method for the separation of fat from meatincludes: (a) providing individual pieces of meat containing lean andfat; (b) subjecting the individual pieces of meat to chilling for a timesufficient to render the fat into a brittle condition; and (c) with amachine, and with the fat in the brittle condition, subjecting theindividual pieces of meat to a crushing force to separate particles offat from the individual pieces of meat.

The method may further include rendering the fat particles into beeftallow. The method may further include exposing the individual pieces ofmeat after crushing to carbon dioxide at or above the criticaltemperature and critical pressure. The method may further includecentrifuging the fat particles after being separated from the individualpieces of meat. The method may further include emulsifying the fatparticles after being separated from the individual pieces of meat. Themethod may further include extracting lean from the fat particles. Themethod may further include separating fat from lean in a centrifuge. Inthe method, the lean matter can be chilled to a temperature to causefreezing of water in the lean, and the temperature of the fat is lowerthan the temperature of the lean. In the method, during step (c), thelean can be left intact. In the method, in step (b), the surfacetemperature of the fat can be lower than the surface temperature of thelean by at least 5° F. In the method, in step (b), the surfacetemperature of the lean can be 26° F. or less, and the surfacetemperature of the fat can be 5° F. or greater, and the surfacetemperature of the fat can be lower than the surface temperature of thelean. The method may further include passing the pieces of meat betweena pair of parallel, adjacent, non-contacting, driven rollers, eachroller having alternating recesses and protrusions around the perimeter,wherein the rollers are arranged to position a recess of one rolleropposite to a protrusion of the second roller, without the rollers beingin contact. In the method, the meat can be beef.

A method for the separation of fat from meat can include: (a) providingindividual pieces of meat containing lean and fat; (b) subjecting theindividual pieces of meat to chilling for a time sufficient to produce adifference in temperature between the fat and lean, wherein the fat ischilled such that the fat is friable and crumbles into finer particleswhen subjected to a crushing force and the lean is cooled to a highertemperature than the fat and the lean is able to withstand a similarcrushing force without substantially crumbling into smaller particles;and (c) with the fat and lean at the temperatures produced in step (b),subjecting the individual pieces of meat to a crushing force to separateparticles of fat from the individual pieces of meat.

In the method, after subjecting the individual pieces of meat tochilling, the temperature at the surface of the fat can be 5° F. to 25°F. In the method, after subjecting the individual pieces of meat tochilling, the temperature at the surface of the lean can be 16° F. toabout 34° F. In the method, the chilling time of the individual piecesof meat can be approximately 2 minutes to 3 minutes. The method mayfurther include transferring the individual pieces of meat and separatedparticles of fat to a vessel and filling the vessel with a fluidcomprising, at least, water, and allowing the particles of fat to risein the fluid and allowing the individual pieces of meat to sink in thefluid, followed by collecting the fat and the individual pieces of meat.The method may further include allowing bone to sink in the fluid to alower elevation as compared to an elevation attained by the individualpieces of meat. The method may further include transferring theindividual pieces of meat and separated particles of fat within aconduit filled with a fluid comprising, at least, water, and allowingthe particles of fat to rise in the fluid and allowing the individualpieces of meat to sink in the fluid while the fluid travels in theconduit, followed by collecting the fat and the individual pieces ofmeat. The method may further include subjecting the individual pieces ofmeat to a crushing force produced by intermeshing teeth to separateparticles of fat from the individual pieces of meat. The method mayfurther include, after separating the particles of fat from theindividual pieces of meat, combining a measured portion of the fatparticles with a measured portion of the individual pieces of meat toachieve a predetermined fat content for the meat. The method may furtherinclude cutting raw meat to a size not exceeding 2 inches in anydimension to produce the individual pieces of meat of step (a). In themethod, after producing the individual pieces of meat, the pieces can bechilled to minimize agglomeration of the pieces into frozen masses. Inthe method, after crushing, the individual pieces of meat in step (c)can comprise predominantly lean meat. The method may further includecontacting the separate particles of fat and individual pieces of meatof step (c) with a flowing fluid comprising, at least, water, in aconduit, and allowing frozen water in the individual pieces of meat tothaw and increase in density, which causes the individual pieces of meatto fall in the flowing fluid, while the fat particles are buoyant in thefluid, and collecting the individual pieces of meat in a lower conduitof a manifold and collecting the fat particles in an upper conduit ofthe manifold. The method may further include separating the fluid fromthe individual pieces of meat and fat particles, weighing the fat, andcombining a portion of the fat with the individual pieces of meat toproduce a meat product of predetermined fat content. The method mayfurther include centrifuging the individual pieces of meat to remove thefluid after separating the fat particles.

Following the bond breaking compression device 1042, the beef particles,once a combination of lean and fat matter, are now smaller particles ofpredominantly all fat and predominantly all lean owing to the breakingof the fat. The lean particles and the fat particles are next separated.Separation may be done in cycles. The lean particles and the fatparticles are accumulated in hopper 1054 until a sufficient amount hasbeen collected to provide for the next separation cycle in theseparation equipment. A vacuum source draws the stream of crushedparticles into hopper 1054. Carbon dioxide gas can be fed into the bondbreaking compression device 1042 to displace air and provide the gas bywhich the vacuum source enables transfer through an enclosed conduit1024 to hopper 1054.

A rotary valve at the bottom of hopper 1054 discussed in associationwith FIG. 1 is used to provide a selected quantity of lean and fatparticles to separation equipment.

Referring to FIG. 1, it is optional to include a small particleseparation in block 14. The small particle separator if used would beplaced directly following the bond breaking compression device 1042 andhopper 1044. In one embodiment, a particle separator system comprises alarge particle separator and a small particle separation. The largeparticle separator applies pressure to the large particles of beef byway of a horizontally disposed assembly of parallel stainless steel barsmounted to a drive means at one end via a stainless steel disc end plateand to a bearing at the opposite end also via a stainless steel disc;the horizontally disposed assembly of bars can rotate in the lowersection of a horizontal trough having a lower profile that follows theunderside profile of the rotating bars. The trough material is stainlesssteel and is perforated with holes of a selected size such that when therotating assembly of bars is positioned so as to have little clearancebetween it and the lower section of the perforated trough, any particlesof greater size than the perforations will be size reduced by crushinguntil the reduction in size allows the particles to fall through theperforations. The size reduced particles are then returned to the largeparticle separator and added to the beef particles and then transferredto a second particle size reduction and from there via screw conveyor orvacuum transfer conduit to transfer to hopper 1054 before separationequipment.

2. Blocks 22, 24, 26, 28, 30, 32, 34, 36, 38, 40

Blocks 22, 24, 26, 28, 30, 32, 34, 36, 38, 40 of FIG. 1 will now bedescribed with reference to FIGS. 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, and12.

The section shown in FIG. 2 between hopper 1054 and hopper 1111 isarranged to separate the lean particles from the fat particles producedin the bond breaking compression device 1042.

In general, separation of the fat particles from the lean (having somefat) particles is done by way of buoyancy separation in a fluid that hasa density lower than that of the lean particles, when the water in thelean particles is not frozen. Separation may also be conducted with afluid that has a density greater than that of the fat particles.Separation may also be conducted with a fluid that has a density in therange between the fat particles and the lean particles. The fluid caninclude water, or water with carbon dioxide, which results in theproduction of carbonic acid. At the temperatures required for bondbreaking discussed above, when fluid is first mixed with the lean andfat particles, the particles will float including the lean particles,and be suspended at the uppermost space available in the fluid and justbelow a surface of the fluid or suspended within the fluid. As thetemperature of the fluid and fat and lean particles begins toequilibrate, which involves the initial lower temperature of the leanparticles increasing, corresponding with the decreasing temperature ofthe fluid, the buoyancy of the lean particles will start to “fail” untilthe lean particles sink toward the base of the fluid leaving the fatparticles floating at the fluid surface or uppermost available space inthe fluid. An increase in the density of the lean particles is seen asthe lean and water thaw, which reduces the volume of lean particles andcorrespondingly increase in density. Fat having a lower content of waterdoes not experience as great an increase in density due to waterthawing.

Before and during the lean particles and fat particles have reachedequilibrium with the fluid, any bone chips that may be present will sinkwhen mixed together with the fluid, thereby providing a convenient meansof separating bone chips first, which will most preferably be arrangedto occur immediately after blending the lean and fat particles with thefluid and before temperature equilibration of the particles or when thelean particle temperature has increased so as to thaw the lean/watercontent of the lean matter upon which shrinkage of the lean will occurcausing it to sink in the fluid. The fat particles, frozen or not, willremain floating at the fluid surface. By lowering the fluid temperaturerelative to the temperature of the lean particles, complete thawing andtemperature equilibration will be delayed and, accordingly, the leanparticles will remain suspended for a longer period and this can assistwith UVc pathogen deactivation as described below.

The lean and fat particles suspended in an anti-microbial fluid ofcarbon dioxide and water (at a suitable ratio of fluid to particles inthe range of 1:1 to 5:1, or 10:1 to 1:10 by weight) can be treated byexposure to UVc light, which is lethal to pathogens when the exposure issufficient. The suspension of frozen lean and fat particles insufficient anti-microbial carbonic acid fluid (or water) can betransferred at a steady rate of transfer through an enclosed/sealedinternally polished (preferably stainless steel) tube within which anelongated, tubular profiled, UVc light source is mounted, in parallelwith the enclosing SS tube. As the temperature of the mixture steadilyequilibrates, the outer surface of the lean and fat particles thaw, ifpathogens are present, the single celled organisms will be at thesurface of the beef particles or suspended in the fluid but, in anyevent, at locations readily accessible to the direct “line of sight” ofthe UVc light source given that the particles revolve while suspended inthe fluid. UVc is lethal to such pathogens as E. Coli 0157:H7 andSalmonellas and such pathogen contamination can be deactivated byadequate exposure to UVc. The particles suspended in the fluid revolverandomly as the mixture is transferred through the UVc apparatus.Pathogens are quickly deactivated when exposed to the UVc light source.

In one embodiment, the process of separating fat from lean is achievedwithin enclosed conduits. After separation of predominantly leanparticles from predominantly fat particles simultaneously in two streamsincluding a first high percentage lean content stream (comprising forexample 93%+/−<1.0% lean with the balance being fat) and a secondinitial fat stream of high fat content (comprising about 85% fat withthe balance being lean). The two streams are transferred within firstand second enclosed conduits, in such a way that the separated lean andfat travel along the respective first and second conduits atapproximately the same velocity (up to about 10 feet per second) to eachother. The conduits in which the respective streams of fat particles andlean particles travel can be measured by flow measuring instruments,such as coriolis instruments. The separated second stream of fat,although separate from the first stream of lean, is in relative closeproximity to the lean stream from which it was separated. In this way,the fat stream can be divided, yet again, into third and fourth streamdivisions wherein at least one of the fat stream divisions can be ameasured third stream division of the initial second stream of fat. Themass of the measured third stream division can be adjusted by varyingthe quantity transferred in the third stream and continuously measuredand/or weighed on a continuous weighing, variable speed conveyor belt.

The measured third stream of fat, or any other stream, can then berecombined with the entire first stream of lean such that the relativeproportions of fat and lean after recombining provide a singlerecombined stream with fat and lean content proportions according to aselected ratio. In other words, for example, by accurately measuring thefat stream division, the resultant lean content of the recombined streamcan be any value less than the lean content (93%+/−<1.0% lean) of thefirst lean stream. A recombined stream lean content of 81%, 85%, 90% orany other value can be produced in this way.

Referring to FIG. 2, the stream of still partially frozen particles(mostly/only fat and mostly/only lean) is drawn in to hopper 1054through vacuum, or otherwise. The bottom of hopper 1054 is connected toa vertical column (seen best in FIGS. 6, 7, and 8). The vertical columnthen connects to the separation manifold 1072, of which there areseveral embodiments, any of which may be used and are interchangeable.Furthermore, the separation equipment need not be a manifold. As analternative to a manifold, a separation vessel may be used, such as theone shown in FIG. 5. The stream traveling through the vertical column iscombined with a pressurized stream of liquid carbonic acid (H2CO3) thatis temperature and massflow controlled, at about 70 psia (but thepressure could be up to about 50 Bar (725 psia)). The liquid carbonicacid is measured, such as with a coriolis instrument. In otherembodiments, liquid carbonic acid may be substituted with water, orother fluids. The liquid carbonic acid that is injected in the verticalcolumn may be generated by combining recovered and stored carbondioxide, as described below, with water. In FIG. 2, vessel 1048 is astorage vessel for carbonic acid fluid.

As described further below, the mixture comprising lean particles, fatparticles, and liquid carbonic acid (or other fluid) are separated intocomponents. The fat is separated and extracted from the fluid andprocessed, optionally, through a particle size reducing apparatus suchas a bowl chopper or even an emulsifier used to break the cell walls butat this stage in the separation process, the fat particles in the fatstream will be size reduced, but not to the extent of breaking cellwalls, but only so as to ensure all red and white colored lean stillpresent with the fat is recovered.

Additionally, the lean particles are separated from the fluid and thenoptionally combined with the fat stream after the fat stream has beenprocessed via a size reduction apparatus such as, but not limited to abowl chopper.

In one embodiment, the combined lean and fat streams including a reducedquantity of carbonic acid (or carbon dioxide and water), altogether in asingle stream is then transferred into a decanter style centrifuge. Thedecanter style centrifuge separates the lean, liquid water and carbonicacid, and fat in typical fashion into layers according to density withthe heaviest (lean) forming a layer around the inner surface of thecentrifuge barrel. The water, carbon dioxide and fat together areseparated from the lean in two entirely separate streams.

The first of several embodiments of a separator following the bondbreaking compression device, including the separation manifold will bedescribed referring to the schematic illustration of FIG. 3, whichincludes equipment similar to FIG. 2. The temperature reduced stream offat and lean particles from the tunnel freezer 1502 is transferred inthe direction shown by arrow 1508 to hopper 1510 with rotary valve,which facilitates transfer of the particle stream from ambient pressureto the pressurized conditions within the separation manifold 1512.Simultaneously, a temperature and mass flow controlled, measuredquantity of carbonic acid (H2CO3) is also transferred from pressurevessel 1526, through coriolis measuring instrument 1528, and along aconduit represented by arrow 1544 into manifold 1512.

The two mass flow and temperature controlled streams of particles andcarbonic acid fluid are blended together in the vertical columnconnected to the bottom of hopper 1510 and the temperatures begin toequilibrate. Initially, however, the frozen condition of the lean andfat result in both lean and fat solids, floating. Any heavy, bonefragments, which are unaffected by the water freezing temperatures, ofthe fat and lean solids sink immediately to the lowermost location inthe manifold it can fall to, which, in one embodiment, is arranged to belocated at the base of the vertical column located directly beneath thehopper 1510 and rotary valve. From the vertical column, the conduit maybe diverted horizontally. In one embodiment, for example, the bonematter may be collected at a bend from the vertical column to thehorizontal conduit.

As the mixture of solids and liquid carbonic acid are transferred alongthe horizontal conduit (“manifold”), temperature equilibration betweenthe solids and liquid increases the density of the high-water-contentlean matter as the formerly frozen water thaws and shrinks. The lean andfat solids quickly separate as temperature equilibration occurs, causingthe density of lean to increase causing the fat and lean solids todiverge as they are carried with the flow of low pH carbonic acid. Thefat matter remains buoyant, carried by the fluid at a higher elevationthan the lean matter and the lean particles fall to the lowermostsection of the conduit through which they are still propelled along thehorizontal conduit by the flow of liquid. The separation manifold isconstructed so that following temperature equilibration of theparticles, a conduit connected directly to the underside of thehorizontal separation manifold and extending downward, allows the leanparticles to be separated from the main fluid stream. An opposingconduit, attached directly to the upper side of the horizontal conduit,allows the fat particles to diverge upwardly and in this way, the fatand lean particles are divided into two streams, wherein the leanparticles (“matter”) follow a conduit that becomes 1531 and the fatparticles (“matter”) follow a path that connects directly to conduit1514.

Enclosed conduit 1531 includes a coriolis measuring instrument 1530through which the entire stream of liquids and solids carried by theconduit 1531 is transferred. Conduit 1531 connects directly to apositive displacement pump 1524, which controls mass flow therethrough.The fat stream carried via conduit 1514 is transferred via coriolismeasuring instrument 1513 and to positive displacement pump 1515.

Two decanter style centrifuges 1532 and 1519 are conveniently located soas to allow direct connection of 1531, which is carrying the streamcontaining lean matter, to centrifuge 1532 and conduit 1514, which iscarrying the stream containing fat matter connects to centrifuge 1519.Centrifuge 1532 is positioned to allow discharge of the lean matter,after separation from the liquid portion of the stream, directly onto acontinuous conveyor 1534, which also includes a weighing station.Similarly, centrifuge 1519 is positioned to allow discharge of the fatmatter after separation from the liquid portion of the stream, directlyonto a continuous conveyor 1521, which also includes a weighing station.The de-liquefied lean matter is carried in the direction shown by arrow1536 and continuously weighed as it is carried toward the collectionconveyor 1550, and the de-liquefied fat matter 1520 carried by weighingconveyor 1521 is weighed as it is carried toward the collection conveyor1550. A coriolis measuring device 1538 is arranged to measure thequantity of liquid separated from the lean matter carried by conduit1531 and transferred through discharge pipe 1522 by centrifuge 1532, andthe liquid separated from the fat matter carried by conduit 1514 andseparated by centrifuge 1519 is then transferred via conduit 1516 andmeasured by coriolis measuring instrument 1517. Coriolis measuringdevice 1528 is arranged to measure the quantity of water with thecarbonic acid added to the combined stream transferred via separationmanifold 1512, and, in this way, the quantity of water remaining withthe lean matter discharged from centrifuge 1532 can be determined bysubtraction after measuring the content of the fat matter carried byconduit 1514 with coriolis measuring instrument 1513 and the quantity ofseparated liquid discharged via 1516 and through coriolis measuringinstrument 1517, thereby enabling determination of the lean content ofthe lean matter deposited by centrifuge 1532 onto conveyor 1534.

Coriolis measuring instrument 1530 continuously measures temperature,mass flow and water content of the stream carried by conduit 1531 andcoriolis measuring instrument 1513 continuously measures temperature,mass flow, and water content of the stream carried by conduit 1514.

The quantity of fat deposited onto conveyor 1521 is already known bysubtracting the quantity of liquids measured by coriolis 1517 from themass flow of matter measured by coriolis measuring instrument 1513. Inthis way, a measured quantity of fat can be returned to the lean mattercarried by conveyor 1534 by restricting the quantity of fat (tallow)carried on conveyor 1521 with the balance of fat matter discharged inthe direction shown by 1518. In this way, the recombined lean and fatstreams can be measured so as to produce a product of selected fatcontent boneless beef carried along conveyor 1550.

Referring back to FIG. 2, the apparatus of FIG. 2 is similar to theapparatus of FIG. 3.

As the mixture of solids and liquid carbonic acid are transferred alongthe horizontal conduit 1072 (“manifold”), temperature equilibrationbetween the solids and liquid increases the density of thehigh-water-content lean matter as the formerly frozen water thaws andshrinks. The lean and fat solids quickly separate as temperatureequilibration occurs, causing the density of lean to increase causingthe fat and lean solids to diverge as they are carried with the flow oflow pH carbonic acid. The fat matter remains buoyant, carried by thefluid at a higher elevation than the lean matter and the lean particlesfall to the lowermost section of the conduit through which they arestill propelled along the horizontal conduit by the flow of liquid. Theseparation manifold is constructed so that following temperatureequilibration of the particles, a conduit connected directly to theunderside of the horizontal separation manifold and extending downward,allows the lean particles to be separated from the main fluid stream. Anopposing conduit, attached directly to the upper side of the horizontalconduit, allows the fat particles to diverge upwardly and in this way,the fat and lean particles are divided into two streams, wherein thelean particles (“matter”) follow a conduit which becomes 1087 and thefat particles (“matter”) follow a path that connects directly to conduit1085.

Enclosed conduit 1087 includes a coriolis measuring instrument 1088through which the entire stream of liquids and solids carried by theconduit 1088 is transferred. Conduit 1088 connects directly to apositive displacement pump 1089, which controls mass flow there through.The fat stream carried via conduit 1085 is transferred via coriolismeasuring instrument 1086 and to positive displacement pump 1101.

Two decanter style centrifuges 1090 and 1107 are conveniently located soas to allow direct connection of conduit 1087, which is carrying thestream containing lean matter, to centrifuge 1090 and conduit 1085,which is carrying the stream containing fat matter connects tocentrifuge 1107. Centrifuge 1090 is positioned to allow discharge of thelean matter, after separation from the liquid portion of the stream,directly onto a continuous conveyor 1098, which also includes a weighingstation. Similarly, centrifuge 1107 is positioned to allow discharge ofthe fat matter after separation from the liquid portion of the stream,directly onto a continuous conveyor 1105, which also includes a weighingstation. The de-liquefied lean matter is carried in the direction shownby arrow 1103 and continuously weighed as it is carried toward thecollection conveyor 1110, and the de-liquefied fat matter carried byweighing conveyor 1105 is weighed as it is carried toward the collectionconveyor 1110. A coriolis measuring device is arranged to measure thequantity of liquid separated from the lean matter carried by conduit1087 and transferred through discharge pipe 1100 by centrifuge 1090, andthe liquid separated from the fat matter carried by conduit 1085 andseparated by centrifuge 1107 is then transferred via conduit 1131 andmeasured by coriolis measuring instrument. Coriolis measuring device1064 is arranged to measure the quantity of water with the carbonic acidadded to the combined stream transferred via separation manifold 1072,and, in this way, the quantity of water remaining with the lean matterdischarged from centrifuge 1090 can be determined by subtraction aftermeasuring the content of the water of the fat matter carried by conduit1085 with coriolis measuring instrument 1086 and the quantity ofseparated liquid discharged via 1131 and through coriolis measuringinstrument, thereby enabling determination of the lean content of thelean matter deposited by centrifuge 1090 onto conveyor 1098.

Coriolis measuring instrument 1088 continuously measures temperature,mass flow and water content of the stream carried by conduit 1087 andcoriolis measuring instrument 1086 continuously measures temperature,mass flow, and water content of the stream carried by conduit 1085.

The quantity of fat deposited onto conveyor 1105 is already known bysubtracting the quantity of liquids measured by coriolis in line 1131from the mass flow of matter measured by coriolis measuring instrument1086. In this way, a measured quantity of fat can be returned to thelean matter carried by conveyor 1098 by restricting the quantity of fat(tallow) carried on conveyor 1105. In this way, the recombined lean andfat streams can be measured so as to produce a product of selected fatcontent boneless beef carried along conveyor 1111.

After the production of a selected fat content boneless beef through anyone of the embodiments described herein there is downstream from member1111, conduit 1130 arranged to transfer a stream of boneless beef havinga selected fat content into a vacuum dehydration and storage vessel1136. Vessel 1136 is mounted on three load cells 1134, 1114, and 1120and is arranged to enable a moisture adjustment by way of vacuumdehydration. For example, moisture can be extracted under very lowvacuum (below 4.7 torr) to ensure the moisture content of the finishedbeef corresponds with the input stream prior to separation. Aftermoisture content correction, processed beef is transferred via conduit1122 to an enclosed carbon dioxide flooded hopper 1124, such as byHandtmann, mounted directly above and to the vacuum stuffer 1138, suchas by Handtmann.

An inline grinder 1126 can be used optionally as the beef is transferredto chub packing machine 1128 (Poly Clip FCA 160 chub packaging system).

Referring now to FIG. 4, a second embodiment of equipment formanufacturing boneless beef having a selected fat content and producedfrom any suitable grade of boneless beef, is illustrated. As with theembodiment illustrated in FIGS. 2 and 3, the embodiment of FIG. 4 is oneof several embodiments of equipment that may follow the bond breakingcompression device, block 12 of FIG. 1. Any of the embodiments describedherein for equipment following the bond breaking process of block 12 ofFIG. 1 is interchangeable with each other embodiment.

FIG. 4 also includes equipment to carry out the process of liquidseparation from lean matter, block 42 of FIG. 1, liquid separation fromfat matter, block 48 of FIG. 1, carbon dioxide recovery, block 56 ofFIG. 1, carbon dioxide collection, block 58 of FIG. 1, and waste watertreatment, block 60 of FIG. 1. The blocks just described are alsoadaptable to be used with other embodiments for separation of fat andlean, and are not limited to being used solely with the separationconfiguration of FIG. 4.

The manifold includes three “in-put” ports at 1706, 1726 and 1610 whichconnect via a series of manifolds and valves to a “main line” conduit1766, which collectively provides a means to separate a mixture ofcarbonic acid and beef particles into the following: (1) a stream ofhigh lean content boneless beef; (2) a stream of beef fat; (3) a streamof recovered, pressurized carbon dioxide; and, (4) a stream of wastewater.

A stream of particle size and temperature reduced boneless beefincluding fat particles and lean particles, such as produced from thebond breaking compression device, is transferred from its place ofproduction via vacuum conveyor 1706 in the direction shown by arrow1700. A vacuum generator (such as a Gardner Denver 4512 blower) isconnected directly to conduit 1704 so as to facilitate pressurereduction in space 1709 by evacuation. Suitably pressurized carbondioxide gas is transferred into port and conduit section 1720, andthrough flow regulator 1724 and coriolis measuring instrument 1722, andthen directly into column 1716 via 1720. The purpose of providing carbondioxide into the sections of vertical column shown as 1716 and 1730 isto maintain a carbon dioxide gas atmosphere for that section of verticalcolumn 1716 and 1730.

A third fluid stream of carbonic acid is provided under selectedpressure of at least 70 psia via conduit 1610 in the direction shown byarrow through heat exchanger 1692 and into conduit section 1744 whichcommunicates directly with coriolis measuring instrument 1740 viaregulator 1742. The flow of carbonic acid transferred via heat exchanger1692 is thereby temperature controlled to a selected temperature withina tight tolerance of not more than + or −5° F. The temperaturecontrolled flow of carbonic acid can be directed via conduit 1738 in thedirection shown by arrow 1737 or, alternatively, via conduit 1748 in thedirection shown by arrow 1750 or a proportion of the flow of carbonicacid can be divided according to any selected proportions via bothconduits 1738 and 1748 in the direction shown by arrows 1737 and 1750,respectively. In this way, a continuous stream of mass flow selectedcarbonic acid is transferred into conduit sections 1730 and 1756 with acarbon dioxide gas atmosphere filling section 1716 of the verticalcolumn. The flow of carbonic acid is generally in the direction shown byarrow 1718, through segments 1730, 1756, and onto section 1766.

Particles of temperature controlled beef, including lean particles andfat particles, are transferred into vertical column 1716 via rotaryvalve 1712 wherein the particles are transferred from fully enclosedhopper 1708 and in particular from space 1709 and the direction shown byarrow 1710. The lean particles and fat particles are transferred intospace 1709 in the direction shown by arrow 1700 by inducing a lower gaspressure within the free space of hopper 1708 enclosed and sealed byhopper cover 1714. Gas from within space 1709 is transferred via conduit1704 in the direction shown by arrow 1702 by way of a suitable Rootesblower or similar gas evacuation pump that is attached to the extension(not shown) of conduit 1704. When a lower gas pressure has been inducedwithin the free space 1709, frozen beef particles comprising the leanparticles and fat particles from the place of production are transferredto the hopper 1708, via a conduit extended from 1706 to the source ofthe particles. Said temperature controlled particles are held withinspace 1709 for a relatively short period of time prior to beingtransferred via rotary valve 1712 and into the carbon dioxide gas filledcolumn 1716. Accordingly, the temperature controlled particles whichcomprise substantially either all lean beef or all beef fat having beenprocessed to break any bond that held the fat matter and lean mattertogether. Therefore, the temperature controlled particles transferredinto vertical column 1716 will fall in the direction shown by arrow 1718and combine with the liquid carbonic acid transferred into the lowerpart of vertical column section 1730 and, after mixing, will be carriedby the rapidly flowing stream of carbonic acid through a 90 degreeconduit section 1756 and toward the horizontal coriolis measuringinstrument 1760 via variable frequency drive controlled Waukeshapositive displacement pump 1758.

Prior to transfer through pump 1758, any very dense bone pieces orfragments, being more dense than the particles suspended in the streamof carbonic acid, will fall to the lower part of any containment such asthe conduit 1756 through which the particles and any bone fragmentscontained therewith is traveling. A vertical section of conduit 1752communicates directly between a liquid filled container with space 1754and the underside of a horizontal section of conduit immediatelyfollowing conduit bend 1756. In this way, the heavy bone particles orfragments will fall via conduit 1752 and into contained space 1754within which liquid carbonic acid has been provided. Followingseparation of bone fragments by transfer through conduit 1752, theremaining particles which are suspended in the liquid carbonic acid, arecarried into the inlet port of Waukesha positive displacement pump 1758and the combined flow of carbonic acid with suspended particles ispumped via Waukesha pump 1758 and through coriolis measuring instrument1760.

The temperature of carbonic acid is controlled prior to transfer intothe separation manifold comprising conduit sections 1756, 1766 andtoward the confluence 1764 of what becomes conduit branches 1822, and1771. Positive displacement pump 1758 is controlled to the extent thatthe fluid with suspended solids carried therein ensures a suitablepressure required to minimize and substantially eliminate any bubbles orvoids in the combined stream as it is transferred through coriolismeasurement instrument 1760. After measurement by coriolis 1760, thecombined stream is transferred into conduit section 1766 and towardconfluence 1764. The temperature of beef particles and the temperatureof the liquid carbonic acid within which the beef particles aresuspended, are arranged such that rapid equilibration can occur aroundthe outer surfaces of each particle. At any event, equilibration of thetemperature of the lean particles occurs before the confluence 1764,such that the density of the lean particles is increased before theconfluence and will fall to the lower section of the conduit 1766, sothat the majority of lean particles will flow into conduit 1771. Thebeef particles and the liquid carbonic acid will ultimately be of thesame temperature, however, time is required to enable the temperatureequilibration and the disclosed method provides the conditions in whichthe fat particles will tend to float and the lean particles will tend tosink when suspended in the liquid carbonic acid. Furthermore, the methodprovides the conditions wherein the fat particles and the lean particlescan be separated rapidly and within less than about 5 seconds aftercombining together.

The density of the lean particles is approximately 66 lbs/cubic footwhen not frozen however when frozen, the density decreases by greaterthan 9 percent which is due to the expansion of water within the leanparticles. Conversely, the fat particles, which contain a low percentageof water of about 11 percent, are not so much affected by temperature asare the lean particles. The density of the fat particles isapproximately 61 lbs/cubic foot whereas the density of the carbonic acidis greater than 62.3 lbs/cubic foot. Accordingly, the fat particles willfloat whether frozen or not, but the lean particles will float only whenfrozen, and when not frozen, lean particles having a density ofapproximately 66 lbs/cubic foot cannot be suspended by the carbonic acidand will therefore sink. However at a point in the temperatureequilibration process between the conditions of lean being eithercompletely frozen or on the other hand completely above the frozencondition temperature of about 28.5° F., the average density of the leanparticle will be greater than the density of the liquid within which itis suspended. In this condition, the center or core regions of each leanparticle can be still frozen or a low temperature and the outer regionsclose to the surfaces of each particle will not be frozen. However, theaverage density will be greater than that of the liquid in which theyare suspended and accordingly those lean particles will sink to a lowerlocation within the carbonic acid. The disclosed methods provide theconditions to enable the separation of fat particles from the leanparticles in a continuous stream but allow the separation of leanparticles to occur when, at least, part of the particles remain in afrozen condition while the remaining part of the particle is an unfrozencondition and to then as quickly as can be achieved, separate the leanparticles from the liquid carbonic acid which carries the lean particlesalong the low elevation conduit branch 1771 shown in FIG. 4.

After transfer through coriolis measuring instrument 1760, the combinedstream of carbonic acid and particles is transferred through conduitsection 1766 and, as the transfer occurs, fat particles and leanparticles separate such that the fat particles occupy an upper region ofany section of the conduit section 1766, whereas the lean particlesoccupy a lower region of the carbonic acid within which the particlesare suspended and, to the extent that the combined stream of fatparticles and lean particles suspended in the carbonic acid becomearranged in such a manner that the fat particles occupy the uppersection and the lean particles occupy the lower section of the conduitsuch that when the combined stream is transferred into the region 1768,the fat particles can be directed in the direction shown by arrow 1784in branch conduit 1822, whereas the lean particles are suspended in aportion of the carbonic acid and transferred into branch conduit 1771that is lower in elevation with respect to branch conduit 1822 in thedirection shown by arrow 1770.

A variable frequency drive controlled Waukesha positive displacementpump 1786 controls the flow of fat particles and fluid into conduit 1822before pump and conduit section 1788 after pump. Pump 1786 achieves flowcontrol by increasing or decreasing the speed at which it operates whichis controlled via a variable frequency drive according to the coriolisinstrument measured fat content of the stream transferred via conduit1788 and through 1790 to conduit section 1789 in the direction shown byarrow 1827. The measured fat content is compared with lean content ofthat portion of the combined lean and carbonic acid stream transferredvia conduit section 1771 and through coriolis instrument 1772 intoconduit section 1773 followed by Waukesha pump 1824, which is alsocontrolled by a variable frequency drive speed control. In this way, themeasurement data recorded of measurements by coriolis instruments 1740,1760, 1790, and 1772 are compared continuously. The measurement ofcarbonic acid flow recorded after transfer via coriolis measuringinstrument 1740 is compared with the recorded data for the same sectionof carbonic acid combined with the particles transferred and combinedwith the carbonic acid via rotary valve 1712. The mass flow, density,and temperature data recorded according to coriolis 1760 is comparedwith the mass flow, temperature, and density data recorded frommeasuring instrument 1740 and the difference between the two sets ofdata will show precisely the amount of particles that have beentransferred and combined with carbonic acid stream through conduit 1610.Additionally, data recorded of mass flow, density, and temperaturemeasurements measured by coriolis instruments 1790 and 1772 can also becompared and by doing so, the lean content within the stream transferredvia conduit 1772 can be determined and the fat content of streamtransferred via 1790 can also be determined and, if the lean content ofthe stream transferred via coriolis 1772 is insufficient, the speed ofWaukesha pumps 1786 and 1824 can be adjusted to compensate for the leancontent by reducing (or increasing) the mass flow of fluid via section1822 and the mass flow of fluid via conduit section 1771 can beincreased (or decreased) and the inadequate proportion of fatcompensated by the addition of a greater quantity of suspended fat withthe stream transferred via conduit 1771. Therefore, it can now be seenthat the coriolis measuring instruments 1740, 1760, 1790, and 1772 canbe used to measure and control Waukesha pumps 1758, 1786, and 1824 so asto direct a fat stream or a lean stream in such a manner as to enablethe lean stream transferred via conduit 1826 in the direction shown byarrow 1818 and into pressurized centrifuge 1838, which rapidly removesthe lean particles from the suspended condition in the carbonic acid.The lean particles are then transferred in a continuous stream viaconduit section 1820 and in the direction shown by arrow 1806 and intofree space 1804 of pressurized vessel 1802.

Vessel 1802 is suspended on load cells mounted on brackets 1808, 1793,and a third load cell not shown. In this way, the contents 1800 ofvessel 1802 can be weighed. The fat content of lean beef 1800 can becontrolled to within + or −1% lean content. Space 1804 is pressurized tomaintain a pressure within the separation manifold and conduits of thesystem as required to facilitate the retention of carbon dioxide in thefluid separated by centrifuge 1838 and transferred via Waukesha positivedisplacement pump 1812 in the direction shown by arrow 1816 via conduit1814 and through coriolis measuring instrument 1842 in the directionshown by arrow 1844.

The separated liquid carbonic acid is transferred via conduit 1846 andinto free space 1950 within vessel 1944. Additionally, the stream ofcarbonic acid and fat suspended therein transferred via conduits 1822,1788, 1789 and 1828 is also transferred into space 1950, wherein thebuoyant fat matter 1948 floats upward to form a segment of fat filling aportion of vessel 1944 and held between the upper horizontal plane 1938and a lower horizontal plane 1946. Vessel 1944 is pressurized andprovides the means for fat particles to accumulate in stratum 1940 andto be transferred through conduit 1928 having an open end 1942 arrangedto enable the pressurized fat particles to be transferred therethroughand through conduit 1928 and 1932 in the direction shown by arrow 1930.

Fat stream transferred there through is then transferred into emulsifier1934 and after emulsification in the direction shown by arrow 1936,which communicates directly with a heat exchanger followed by decantercentrifuge which separates the oil from any remaining solids in thestream. Vessel 1944 comprises an elongated vertically disposedcylindrical tube with a dome closing the upper end of a tube and a coneat the lower end. A gate valve is provided at the lower end of the lowercone and a section of, for example, 6 inch diameter stainless steel tube1924 is mounted at the upper end to enable the transfer of carbondioxide gas via conduit 1904 and in the direction shown by arrow 1902.

Liquid carbonic acid from the separation process of the centrifuge 1838and liquid carbonic acid containing fat particles is transferred to thelower section of the pressure vessel 1944, and the two streams areallowed to combine and any suspended solids separate by stratification,wherein a small amount of lean matter 1840 may still accumulate at thelowermost section of the vessel 1944 while carbonic acid is allowed toaccumulate in a space 1950 at the middle section of the vessel 1944. Fatsegment 1940 can therefore accumulate by flotation to the upper surfaceof carbonic acid liquid 1950. The location of inlet ports (2) and outletports (4) is arranged to facilitate the removal of accumulated andstratified fat via port 1942, stratified lean 1840 via conduit 1830,liquid carbonic acid via conduit 1926 in the direction shown by arrow1848. Gas is transferred from space 1864 via conduit 1924, 1904 in thedirection shown by arrow 1902 and conduit section 1876 in the directionshown by arrow 1878.

The stream of carbonic acid discharged from space 1950 within vessel1944 is transferred into heat exchanger 1918 via conduit 1906, whereinthe temperature of the carbonic acid stream is increased by at least 30°F. with a heating medium entering exchanger 1918 via 1914, such that thecarbonic acid will decompose into water and carbon dioxide. The streamof decomposing heated fluid is transferred into vessel 1872 via conduit1908 and port 1870 into space 1877 in the direction shown by arrow 1912.Carbon dioxide gas is then free to form bubbles and ascend upwardly inthe direction shown by arrow 1874 and to accumulate in space 1898 and1896 of vessel 1872. Carbon dioxide gas can then be transferred viaconduit 1894 in the direction shown by arrow 1892 to Blackmer compressor1888 and after compression to about 300 psia into heat exchanger 1882,via conduit 1890, and then via conduit 1886 in the direction shown byarrow to a suitable storage vessel prior to reuse. The shell side oftube in shell style heat exchanger 1882 is filled with chilled fluidtransferred therein via conduit 1884 and the spent fluid returned to itssource via conduit 1880 in the direction shown by arrow 1881, in orderto cool the compressed carbon dioxide gas after compression.

Referring again to FIG. 4 and in particular vessel 1802. Lean beef 1800accumulates in the lower portion of the vessel while carbon dioxide gaspressurized to a selected pressure but most preferably around 70 psiaaccumulates in space 1804 and 1810. Carbon dioxide gas is transferredinto space 1804 with the lean stream and excess gas is released viaconduit 1794 in the direction shown by arrow 1819 wherein said conduit1794 communicates directly with conduit 1900 in the direction shown byarrow 1910 to connect with the carbon dioxide gas exiting vessel 1944.Excess gas accumulating in space 1864 and 1924 of vessel 1944 above thefluid surface 1938 is transferred through conduit 1904 in the directionshown by arrow 1902 and arrow 1878 communicating directly with conduit1894, thereby enabling transfer of excess gas from vessels 1872, 1944,and 1802 to carbon dioxide compressor 1888, which elevates the gassupplied thereto at a pressure of greater than 25 psia compressing thecarbon dioxide gas supply to around 300 psia which is then transferredvia conduit 1890 and heat exchanger 1882 to suitable storage vessels(not shown) in the direction shown by arrow 1886. Arrows 1884 and 1881represent the introduction of a cooling medium in the heat exchanger1882 for cooling the carbon dioxide gas following compressor 1888.

Lean 1800 in vessel 1802 is progressively transferred via bottom port1798 along conduit 1796 and 1792 in the direction shown by arrows toport 1780 and into enclosed hopper 1776. Enclosed hopper 1776 with cover1778 is sealed and may be pressurized to any suitable pressure up toaround 70 psia or ambient pressure however lower flange 1782communicates directly with a vacuum filler such as a Handtmann VF620 andboneless beef having a predetermined fat content can thereby betransferred from holding hopper 1776 to any selected subsequent processsuch as chub packaging or anoxic case ready packaging in the directionshown by arrow 1774.

Heat exchanger 1918 is arranged to provide a means of heating the liquidcarbonic acid transferred therein via conduit 1906. Hot fluid heated toa selected temperature of not more than 200° F. is transferred into theshell side of shell and tube heat exchanger 1918 so as to circulatearound the tube side through which carbonic acid is transferred. Spentheating fluid is then discharged and returned to its source via conduitin the direction shown by arrow 1920 while the heated fluid carbonicacid, carbon dioxide gas and water, is transferred via conduit 1908 intospace 1879 of vessel 1872. Waste water is discharged via port 1868 alongconduit 1866 to a suitable disposal such as a sewer in the directionshown by arrow 1865.

3. Separators

This section more particularly describes the separators. As used herein,a separator is the equipment arranged to separate from a mixturecontaining fluid, fat particles, and lean particles, at least one streamof fluid and lean, and preferably separate two streams one of leanmatter and one of fat matter. Particles of fat are formed, as discussedabove, through a bond breaking process that breaks frozen fat from beefparticles, leaving mostly lean on the remaining particle. The firststream contains fluid and the majority of the lean particles, and thesecond, contains fluid and the majority of the fat particles. The fluidcan be carbonic acid, or a mixture of water and carbon dioxide, or otherfluids mentioned herein. It is to be appreciated that at this stage ofseparation, small amounts of lean particles may be entrained in thefluid stream of fat particles, and small amounts of fat may be entrainedin the fluid stream of lean particles. Indeed, the retention of somefat, and preferably a desired content of fat content in the fluid streamof lean particles is desirable to produce a lean product of desired fatcontent. The fat may also be present on lean particles that fails toseparate from the lean matter during the bond breaking process. Thefirst and second fluid streams mentioned correspond to blocks 32 and 36of FIG. 1.

It has been determined that the fat matter of a frozen, diced piece ofbeef (or other meats) can be separated from the lean matter by crushingthe frozen beef so as to fracture the fat (fatty adipose tissue).

The fat matter behaves quite differently to the lean matter,particularly when frozen to a temperature below about 25° F. to about10° F. or lower, but not to such a low temperature that will cause thelean to become brittle. When reduced size beef pieces are frozen in thisway, the fat can be shattered and will crumble providing a suitablemeans of separating the fat matter from the lean matter initiallypresent in the beef pieces. Typically, this method of separationproduces much smaller particles of fat while the lean particle sizeremains largely unaffected. It is therefore possible to separate leanfrom fat by freezing, shattering the fat matter, and then transferringthe resultant stream of material through a vibratory sieve, which willallow the small fat particles to pass through a sieve while transferringthe larger lean pieces to another hopper; however, the sieve is not ascost effective as using the method of flotation in an anti-microbialcarbonic acid.

The separation of bone fragments, lean and fat relies not only on therespective densities of bone (cartilaginous matter or bone), fat, lean,and fluid carbonic acid to cause separation when all are maintained at asimilar temperature, above the freezing point of water, but also whenthe water-containing lean and bone fragments are at a temperature belowthe freezing point of water.

Table 1 (below) lists the densities of; firstly, several beef componentsincluding bone, lean beef, fat and cartilaginous bone, at both above andbelow the respective frozen condition; and also carbonic acid and water.It can be seen that the densities of the frozen, water-containing beefcomponents of lean and fat have lower densities compared to theirrespective unfrozen condition. This physical variation is because waterexpands when it freezes. The temperature at which beef freezes is atabout 29° F. or below. Beef fat will float in water or carbonic acidwhether it is in frozen condition or not but, as can be seen in Table 1,frozen lean beef having a density of about 59 lbs per cubic foot willfloat in water and/or carbonic acid which have densities of about thesame value, about 63 lbs per cubic foot; however, when the lean beef isnot frozen, its density increases to about 65 lbs per cubic foot andtherefore will sink when suspended in water or carbonic acid.Furthermore, the introduction of initially frozen water-containing beefinto such fluids at a higher temperature than the frozen beef will causesuspension or floating of the beef initially. As the temperaturesequilibrate, this causes thawing of the water in the beef with anattendant decrease in volume and increase in density, which will causethe beef or lean to sink in the fluid. Neither bone nor cartilaginousbone contain significant quantities of water and their respectivedensities are not significantly affected by freezing followed bythawing; both are more dense than fat or lean beef.

The separation methods described herein employ the density variationsdescribed above to provide an effective method of dividing a quantity ofbeef into fractions comprising the separated components of bone, leanbeef and beef fat. Beef is used only for purposes of illustrating thevarious embodiments, it is to be appreciated that other meats, includingpork, chicken, and fish may also be used in the disclosed methods.Furthermore, bone or cartilaginous bone may or may not be present insome embodiments.

TABLE 1 APPROXIMATE DENSITIES & WATER CONTENT OF SPECIFIED MATTERPhysical Density % Water Density Matter @ 4° C. Content when frozen Bone118.6 lbs/cu′    0% 118.6 lbs/cu′   Cartilage 80 lbs/cu′  0% 80 lbs/cu′Lean Beef 64 lbs/cu′ 59% 59.6 lbs/cu′   Lean Beef 64 lbs/cu′ 73% 58.6lbs/cu′   Carbonic Acid 63 lbs/cu′ 70% 58 lbs/cu′ Water 62 lbs/cu′ 100% 57 lbs/cu′ Ice 57 lbs/cu′ 100%  57 lbs/cu′ Beef Fat 55 lbs/cu′ 11% 54.5lbs/cu′  

Low pH carbonic acid can be manufactured in block 24 of FIG. 1 bycombining a quantity of carbon dioxide vapor/gas with clean purefiltered water at a ratio of weight equal to about 1 part carbon dioxideto two parts water at a pressure of up to about 150 psia which willprovide carbonic acid having a pH of about 2.6 units. Pressure of about125 psia to 150 psia results in a pH value of the carbonic acid in theorder of between 3.4 and 2.6 pH. The carbonic acid may be used as afluid in which to separate the respective components of beef.

Embodiment 1

One embodiment for separating respective streams of lean and fatparticles may use the vessel illustrated in FIG. 5. FIG. 5 shows anapparatus 500 designed for the separation of bone fragments, lean beefand fat particles.

The arrangement of the vessel 500 illustrated in FIG. 5 comprises anarrangement of 5 pressure vessels, 501, 502, 503, 504, and 505 that areconnected together to provide an assembly of pressure vessels andconfigured to allow communication between the vessels but also havingvalves 511, 512, 513, 514, 515, and 516 provided at the juncture betweenany two vessels so as to facilitate communication between the vessels orthe isolation of each vessel as desired.

Spaces 510 and 590 have a combined volume sufficient to accommodate afull charge of beef (meat) pieces, wherein the charge has a volumeand/or mass equal to the maximum quantity of beef pieces that can beprocessed in one cycle of the apparatus 500.

The space 508 is equal to approximately 4 times the combined space of510 and 590, and the space 509 is approximately equal to the maximumquantity of beef fat that can be processed by the separation apparatus500.

The arrangement of vessel 500 as shown in FIG. 5 is constructed withvessel 502 at the upper end of a vertically disposed arrangement withvessel 503, which is centrally located. Vessels 504 and 505 are alsovertically disposed below vessel 503, and loading vessel 501 is mountedabove and to the side of the main separation vessel 503.

The sequence of operation is as follows:

With valves 511 open and valve 513 closed, a charge of carbonic acid,lean particles, and fat particles, and bone, frozen to below 29.5 F andmost preferably below 27 F and as low as 15 F, are transferred intospace 510, after which valve 511 is closed. Carbon dioxide gas isprovided into voids remaining in space 510 up to a pressure of about 150psia. With valves 512, 513, and 514 closed, space 508 is pressurized toabout the same pressure as space 510 with carbon dioxide and valve 513is opened such that aperture at 521 is fully open, thereby allowing thecontents of space 510 to transfer by gravity feed into the lower regionof space 508, after which valve 513 is fully closed. Space 510 can benow reloaded in readiness for the next loading cycle of space 508.

Carbonic acid, water, filtered water, distilled water, potable water,water having been transferred through reverse osmotic treatment toproduce potable water, or any suitable antimicrobial organic acid oralkali having a density of about 62-63 lbs per square foot at atemperature of about 40 F to 60 F is transferred into space 509, theremaining space in 508 and spaces 556 and 506 under pressure at about150 psia. The antimicrobial fluid is recycled through ports 550, 584,542, 544, and 592 at such a rate of flow so as to create turbulence andagitation of the mixture of particles which are now suspended in theantimicrobial fluid that fills the entire inner spaces of vessels 502,503, 504, and 505. The valves 512, 514, and 515 are opened while thebeef particles remain substantially frozen and the agitation is stoppedso as to allow bone fragments to settle by sedimentation into thelowermost space 505. Before the temperature of the beef particles withinvessels 502, 503, 504, and 505 equilibrates with the antimicrobial fluidin which it is suspended to an equilibrated temperature of above 32 F,the valve 515 is closed to isolate all bone particles or chips in space506. When the temperature of lean and fat matter of the beef particlestransferred into space 508 is below the freezing temperature of thewater contained within the particles, both fat and lean particles willremain suspended in the fluid because the density of the particles isless than the density of the antimicrobial fluid; however, when thetemperature of the fluid and particles equilibrates, the lean particleswill sink into space 504 and below valve 514 at which time valve 514 isclosed so as to isolate spaces 508 and 504. Fat particles float upwardinto space 509 after which valve 512 is closed so as to isolate space509.

The quantity of fat particles at about 34 F or more, which are nowenclosed within space 509, is extracted, most preferably by vacuum, viaport 594 and through conduit 532 in the direction shown by arrow 536.

Bone chips and unwanted cartilaginous bone is removed via port 564and/or via aperture 517 after valve 516 is opened.

Lean beef (meat) is extracted via port 518 in valve 515 and through port517 in valve 516, and then through conduit 566 and port 568, andtransferred for further processing into edible food.

Fluids can be extracted through spaces 558, 570, after passing throughholes 554, 572, 560, and also via ports 562 and 564, for water andcarbon dioxide recovery for subsequent recycling prior to removal ofsolids as described above. Vessel 504 can include an outer cylindricalshell that tapers to a smaller diameter at the bottom. Within the vessel504 are provided a series of frustoconically shaped vessels numbered576, 574, 575 and 507 from top to bottom, wherein the wider “bases” areoriented towards the upper portion of vessel. The side with the smallerdiameter of the frustoconically shaped vessel fits within the side ofthe larger diameter of an adjacent vessel. This difference in diameterallows the placement of annular screens with holes 554, 572, and 560 inthe annular space between the frustoconical vessels. Furthermore, thefrustoconical shape creates spaces between the frustoconically shapedvessels and the interior of the outer shell of vessel 504.

Embodiment 2

A manifold as used herein when referring to a separator takes the fromof a conduit that branches from a main conduit transferring the mixtureof fluid, fat and lean particles into at least two or more conduitbranches. The two or more conduit branches are, respective to eachother, different in elevation, so that matter that is lower in the mainconduit may be transferred to the low conduit branch, while matter thatis higher in the main conduit is transferred to the higher conduitbranch.

Referring to FIG. 6, a manifold 122 used as a separator is arrangedbetween a feed hopper 86 at ambient pressure, and rotary valve 92 (block22 of FIG. 1) with driver 88 on the in-put end of the manifold assemblyand the spent liquid centrifuges 162 and 180 at the output. The manifoldseparator 122 may be used as the separator block 30 of FIG. 1.

Hopper 86 is loaded most preferably by way of an enclosed conduit withfrozen beef particles in the direction shown by arrows 80 from the bondbreaking compression device. The frozen beef particles refer to the fatand lean particles produced by the bond breaking compression device,block 12 of FIG. 1. Hopper 86 is attached directly to the upper side ofa rotary valve 92 which provides the means of transferring the frozenbeef particles from hopper 86 into vertically disposed column conduit106 when the pressure within conduit 106 is maintained at a constantelevated pressure such as 50 psia or 70 psia. If required, carbondioxide gas is injected into hopper 86 via connection tube 82 withon/off valve 84 in the direction shown by arrow 90.

Conduit 106 is attached directly to the underside of rotary valve 92 viaa connection member 94 into which carbon dioxide gas can be injected viatubes 100 and 98 in the direction shown by arrows 102 and 96respectively. Frozen beef particles 104 including fat and lean particlesare shown descending in the direction shown by arrow 200 toward mixingsection 116 between carbonic acid injection ports 112 and 110 via whichcarbonic acid is injected in the directions shown by arrows 114 and 108.The blended beef particles including fat and lean particles and carbonicacid fluid 118 continue downward through reducing conical member 120 andaround radius 122 in the direction shown by arrow 124.

Immediately after the 90 degree bend in the conduit 122 at the lowermostunderside point, tube 119 is attached and communicates directly withpressurized vessel 123 filled with fluid 117. In one embodiment, thetube 119 is configured to be at or approximately tangent to thelowermost end of the bend 122. However in other embodiments, the tube119 can be placed at a horizontal run of conduit, wherein the tube 119branches at an angle less than or equal to 90 degrees. The purpose oftube 119 and vessel 123 is to allow the heavy bone fragments thatoccasionally occur in boneless beef to be separated by following conduit119 into vessel 123 and accumulating therein as bone or cartilage matter121 thereby being removed from the boneless beef. It is to beappreciated that the frozen or partially frozen lean particles by thetime they pass above tube 119 have not yet thawed sufficiently to causetheir density to increase and fall to the lower side of conduit 122 andare still suspended in the mixture. Thus, this avoids the lean particlesbeing carried with bone and cartilage into tube 119 and vessel 123.

The temperature of the carbonic acid injected via inlet ports 112 and110 must be sufficient to elevate the temperature of the boneless beefparticles including fat and lean particles such that any water containedtherein will thaw. The temperature of the water contained within theboneless beef particles should be on the order of 32-34° F. afterequilibration. The proportion of carbonic acid expressed as a ratio tothe frozen beef particles including fat and lean particles should be inthe range of not less that 1:1 and not more than 6:1, wherein, with aratio of 1:1, the quantities are equal or not more than six partscarbonic acid and one part beef particles.

Density of beef tallow or fat is approximately 55 lbs/cubic foot whereasthe density of lean beef is approximately 66 lbs/cubic foot when notfrozen. When frozen, lean beef has a density of around 60 lbs/cubic footand beef fat around about 54 lbs/cubic foot. Given that carbonic acidhas a density of approximately 62.4 lbs/cubic foot when frozen, bothlean beef and beef fat will float after immersion in carbonic acid.However lean beef with a density of 66 lbs/cubic foot when not frozenwill therefore sink when no longer frozen. The apparatus shown in FIG. 6is arranged to take advantage of these variations in density by allowingbone fragments to be separated from the mixture via conduit 119, whileboth beef fat and lean 128 are still frozen and therefore will flowfollowing the upper side of conduit 130. As the mixture of carbonic acidand beef particles including fat and lean particles flow through conduit130 in the direction shown by arrow 126, lean particles increase intemperature such that the water contained therein will begin to thaw andis no longer frozen. As this occurs, the density of the lean particlesincreases so that the lean particles fall to the lower side of theconduit 130, thus, facilitating the separation of the lean particles viaa low elevation branch conduit 140 in the direction shown by arrow 136and the lighter fatty particles follow in the direction shown by arrow132 through a higher elevation branch conduit 134. However, anyparticles that remain suspended in the carbon dioxide will continue inthe direction shown by arrow 202 through a third middle elevation branchconduit 138. The third middle elevation branch conduit 138 thenbranches, so that one branch reconnects with the higher elevationconduit branch 138, and one branch from middle branch 138 reconnectswith the lower elevation branch conduit 140. Middle elevation branchconduit 138 provides additional length for fat particles and leanparticles to diverge into upper and lower spaces in the conduit.

High and low elevation conduits 134 and 140 then connect with respectivepumps 144 and 154, which then feed respective centrifuges 162 and 180.High and low elevation conduits 134 and 140 may include respectivemeasuring instruments, such as coriolis flow meters, to measure flowrate, density and temperature to derive a fat or water content, andthese measurements may be used to adjust the flow rate of pumps 144,154. A fourth branch conduit 113, optionally, of smaller diameter thanbranch conduit 134 communicates at a 45 degree disposition with positivedisplacement pump 115. Conduit 113 branches from conduit 134 at the endof a bend before conduit 134 returns to a horizontal run. Positivedisplacement pump 115 controls the amount of fluid with suspended solidsthat travel in the direction shown by arrow 107. As the lighter fattyparticles change direction following the conduit 134 and shown by arrow142, the lightest smallest fat particles are drawn into conduit 113 andin this way substantially pure fat particles substantially excludingprotein or connective tissue can be drawn into conduit 113 in thedirection shown by arrow 107. The remaining lighter particles but stillheavier than particles in conduit 113 continue in the direction shown byarrow 142 and into positive displacement pump 144 which controls themass flow of suspended solids and fluid into centrifuge 162.

The heavier lean particles and carbonic acid flow along conduit 140 inthe direction shown by arrow 150 and into positive displacement pump 154which controls the mass flow of the solids and fluids into centrifuge180. Both centrifuges are arranged to remove the spent carbonic acidfrom the streams of solids which are discharged via separate ports.Thus, these fulfill the function of blocks 42 and 48 of FIG. 1. However,other liquid separators described herein may be substituted for thecentrifuges 162 and 180, such as buoyancy separators. The liquidcarbonic acid separated from the solid fat particles in centrifuge 162is discharged via a port in the direction shown by arrow 158 and theliquid carbonic acid separated from the solid lean particles incentrifuge 180 is discharged via port 155 in the direction shown byarrow 156. The fat particles are discharged via a port at the oppositeend of the centrifuge in the direction shown by arrows 170 and 174 andthe lean particles are discharged via port 184 in the direction shown byarrows 186 and 182. Because the fat content of lean particles travelingin conduit 140 has been measured and adjusted through the control ofpumps withdrawing a greater or lesser volume of the fat particles, theseparated lean particles may be produced having a desired fat content.Alternatively, the liquid free fat and lean particles exitingcentrifuges may be weighed and combined in desired proportions to arriveat a desired fat content product. The liquid carbonic acid dischargedfrom centrifuges may be sent to a carbon dioxide recovery process asdescribed above, and any carbon dioxide gas vented from any equipmentmay be directed to a carbon dioxide gas treatment process andcompression as described above to be reused to make carbonic acid or asthe carbon dioxide gas injected into the bottom of rotary valve 92through ports 98 and 100.

Embodiment 3

Referring to FIG. 7, a manifold used as a separator is arranged betweena feed hopper 1300 at ambient pressure, and rotary valve 1300 (block 22of FIG. 1) with driver 1302 on the in-put end of the manifold assemblyand the spent liquid centrifuges 1362 and 1386 at the output. Themanifold separator may be used as the separator block 30 of FIG. 1.

The assembly and operation of the apparatus shown in FIG. 7 is similarto the operation of the apparatus shown in FIG. 6, however the fatstream is processed differently in the apparatus shown in FIG. 7.

As can be seen in FIG. 7, the process is similar to FIG. 6 up to the 90degree bend following the introduction of carbonic acid fluid throughports 1326 and 1330. After the 90 degree bend 1348, the horizontalconduit 1410 with fluid being transferred in the direction shown byarrow 1414, diverges into two conduits with a lower branch conduit 1354and an upwardly disposed branch conduit 1352. In this way, leanparticles and a proportion of carbonic acid are directed in thedirection shown by arrow 1404 through downwardly inclined branch conduit1354 and then horizontally in section 1402. However, the fat particlesand a proportion of carbonic acid is transferred upwardly and then inthe direction shown by arrow 1336 to positive displacement pump 1334which pumps under pressure the fat with fluid in the direction shown byarrow 1332, via conduit 1342 and into “emulsifying” device 1344. Device1344 is described herein in association with FIGS. 11 and 12 and isconstructed for the purpose of separating any fat matter that remainsconnected to connective tissue. The fluid and fat in the fat streamdiverted and processed by pumping via device 1344 is subjected to anexplosive force when transferred through a narrow annular slot which“scrapes” fat from other more pliable and tough matter. The processedstream is then transferred via a conduit in the direction of arrows 1346and 1412 through a horizontal conduit 1350. Horizontal conduit 1350transferring emulsified fat particles and other tissue, then branchesinto three branches of high, middle, and low elevations.

The high elevation branch conduit 1338 connects to pump 1358 followed bycentrifuge 1362. The middle elevation branch conduit 1339 has a shorthorizontal run and then branches into an upwardly inclined high branch1406 that reconnects with high elevation branch 1338, and a downwardlyinclined low branch 1396 that reconnects with initial branch 1402carrying the lean particles. The low elevation branch 1408 from conduit1350 connects to branch 1402 carrying lean particles 1402 at a locationbefore the connection from middle elevation conduit downwardly inclinedbranch 1396. In this way, the emulsified materials are connected withthe separation manifold upstream of upward and downward conduits whichallow heavier lean components to sink into conduit 1392 and lighter fatparticles to conduit section 1338 and forward to respective centrifuges1362 and 1384.

High and low elevation branch conduits 1364 and 1400 before pumps 1358and 1390 may include respective measuring instruments, such as coriolisflow meters, to measure flow rate, and density to derive a fat content,and these measurements may be used to adjust the flow rate of pumps 1358and 1390 that feed centrifuges 1362 and 1386. Both centrifuges 1362 and1386 are arranged to remove the spent carbonic acid from the streams ofsolids which are discharged via separate ports. Thus, these fulfill thefunction of blocks 42 and 48 of FIG. 1. However, other liquid separatorsdescribed herein may be substituted for the centrifuges 1362 and 1386,such as buoyancy separators. The liquid carbonic acid separated from thesolid fat particles in centrifuge 1362 is discharged via a port in thedirection shown by arrow 1358 and the liquid carbonic acid separatedfrom the solid lean particles in centrifuge 1386 is discharged via aport in the direction shown by arrow 1388. The fat particles aredischarged via a port at the opposite end of the centrifuge 1362 in thedirection shown by arrows 1374 and 1372 and the lean particles aredischarged via a port 1382 in the direction shown by arrows 1380 and1384. Because the fat content of lean particles traveling in conduit1400 has been measured and adjusted through the control of pumpswithdrawing a greater or lesser volume of the fat particles, theseparated lean particles may be produced having a desired fat content.Alternatively, the liquid free fat and lean particles exitingcentrifuges may be weighed and combined in desired proportions to arriveat a desired fat content product. The liquid carbonic acid dischargedfrom centrifuges may be sent to a carbon dioxide recovery process asdescribed above, and any carbon dioxide gas vented from any equipmentmay be directed to a carbon dioxide gas treatment process andcompression as described above to be reused to make carbonic acid or asthe carbon dioxide gas injected into the bottom of rotary valve 1309through ports 1398 and 1318.

Embodiment 4

Referring now to FIG. 8, another embodiment of a separation manifold1600 is illustrated. The separation manifold 1600 can be used as theseparator block 30 mentioned in association with FIG. 1. In thisembodiment, the apparatus is intended to enable the continuous flow of astream in the direction shown by arrow 1658 within conduit 1616 and into manifold 1662, wherein the stream comprises solids introduced viarotary valve 1608, which allows a controlled flow of solids from hopper1606 and contents 1684 and into space 1714, immediately above fluidintroduced via conduit 1654, 1620, and 1648, in the direction shown byarrows 1645 and 1618.

Fluid introduced into vertical column at 1712, such as carbonic acid, ismeasured by a coriolis measuring instrument 1652. Controlled flow ofcarbon dioxide vapor is introduced via conduits 1636 and 1610 and thetotal can be measured by a coriolis measuring instrument 1640. Anadditional coriolis instrument provided in Section 1708 (but not shown)measures the combined stream comprising carbonic acid fluid, leanparticles, and fat particles, flowing in the direction 1658. Theproportion of fluid, solids, and carbon dioxide gas are adjusted toachieve optimal operation of the apparatus. If too much carbon dioxideis present it will not dissolve in the fluid and will affect theaccuracy of coriolis measuring instruments, therefore, the flow ofcarbon dioxide vapor and carbonic acid transferred through conduits 1636and 1654 respectively must be measured and controlled accurately toensure any gas introduced via conduit 1636 and 1610 will dissolve.

Solids at 1714 combine with the carbon dioxide vapor which acts as abarrier between the fluid entering at 1712 through ports 1618 and 1644to ensure that the fluid cannot come into contact with the underside ofrotary valve 1608. The combined stream within conduit 1616 is measuredby coriolis measuring instrument installed at space 1708, followed by alarge diameter coriolis measuring instrument.

In this embodiment, the manifold is a large diameter conduit 1624 havinga series of horizontal plates. The horizontal plates are alignedparallel to each other within the conduit 1624. The higher a plate is inelevation, the more the plate is located forward of the adjacent platelower in elevation. Thus, each horizontal plate has a forward end (orproximal side) that terminates closer from the entrance of conduit 1624,than a horizontal plate below it.

The solids introduced into the conduit 1624 enter space 1622 aftertransfer through a positive displacement pump and coriolis (both notshown) inserted in space 1708. Within space 1622, the lean solidsparticles have preferably reached equilibrium of temperature with thefluid to allow the increase in density that comes with the thawing offrozen water within the lean matter. The pump delivers the fluid mixturewith suspended solids at a controlled rate into the space 1622 so as toenable the fat content to elevate and stratify up against the undersideof the upper section of manifold 1624 whereas the heavier solids such aslean will sink and accumulate at the lower section near location 1662.

The series of horizontal plates within manifold 1624 are provided toensure lateral flow does not facilitate mixing of the separatedstratified particles. The distal side of manifold 1624 branches intothree conduit branches, including high conduit branch 1694 which ishighest in elevation, low conduit branch 1672, which is lowest inelevation, and middle conduit branch 1682, which is between the low andhigh conduit. One horizontal dividing plate 1683 can extend distally tocompletely separate the low conduit branch 1672 form the middle conduitbranch 1684. The dividing plate 1683 separates the horizontal platesinto an upper array and a lower array. The lower array feed into lowconduit branch 1672 only, while the upper array variously feeds both thehigh 1694 and middle 1682 branch conduits.

Within manifold 1624, a pivoting plate 1770 is provided. A horizontaland stationary dividing plate 1696 is located distal to the pivotingplate 1700. The horizontal plate 1696 separates the high conduit branch1694 from the middle conduit branch 1682. The proximal end of pivotingplate 1770 can be positioned at the end of any of the distal ends of thehorizontal plates that comprise the upper array of horizontal platesabove the dividing plate 1683. The pivoting plate 1770 thus can bepositioned so that one or more of the upper array horizontal plates feedinto the high conduit branch 1694, while the remaining horizontal platesof upper array feed into the middle conduit branch 1684. As illustrated,the fluid with solid particles collected in space 1702 above the plate1700 will flow toward the high conduit branch 1694, while the fluid withsolid particles collected in space 1680 below the plate 1700 will flowtoward the middle conduit branch 1682. It is believed that the higher aparticle is in fat content, the higher in elevation the fat particlewill float in the fluid. Thus, the higher the pivoting plate 1770 ispositioned, the higher the fat percentage will be the stream collectedin the high conduit branch 1694.

Plate 1700 can be positioned as shown by movement indicated by arrows1704 and 1706. High conduit branch 1694 has a coriolis measuringinstrument 1692. Middle conduit branch 1682 has a coriolis measuringinstrument 1688. Low conduit branch 1672 has a coriolis measuringinstrument 1674. In this way, fat content of suspended solids flowingalong high conduit branch 1694 can be either increased or decreasedaccording to measurements recorded by coriolis measuring instrument 1692or 1688. Coriolis measuring instruments 1674, 1688, and 1692 can alsocontrol fat content of each of the streams represented by arrows 1690,1686, and 1678 when positive displacement pumps are connected directlyinline with conduits 1694, 1682, and 1672.

Embodiment 5

Referring to FIG. 9, the side elevation of a manifold 2528 is shown withfour cross section views A-A, B-B, C-C, and D-D taken along the length.The embodiment of a manifold 2528 illustrated in FIG. 9 may be appliedto anyone of the manifold separators illustrated in FIGS. 2, 3, 4, 6, 7,and 8.

The manifold 2528 is arranged to enable the separation of a singlestream of particles suspended in a fluid such as carbonic acid whereinparticles, some of which are approximately 100% fat, some areapproximately 100% lean, and others are a combination of fat and lean invarying percentages between 100% lean and 100% fat. Arrows 2522 show thedirection in which the stream with suspended particles is flowing withinthe conduit 2528 under selected pressure such as 70 psi or severalhundred psi such as 200, 300, 400 or more. The manifold separator 2528includes a changing cross-sectional profile as the separation manifoldapproaches the diverging conduit branches. The manifold 2528cross-sectional aspect ratio (the width divided by the height) decreasesfrom a proximal to distal position. This decrease in the aspect ratioassists to provide better separation.

At cross section A-A shown as 2508, the separation manifold 2528 has acircular profile 2556. At cross section B-B shown as 2510, theseparation manifold 2528 is elongated in the vertical direction as shownin 2562. At cross section C-C shown as 2512, the separation manifold2528 is elongated even further, and at cross section D-D, the separationmanifold 2528 is even more so.

The diameter of cross section A-A 2556 may be in the order of 6 incheswhereas the width at section D-D of the manifold may be 1 inch to 1½inches by approximately 6-8 inches in height and the manifold profilebetween section A-A and D-D gradually changes in such a way that nosharp corners are created. The fluid stream with suspended particles incarbonic acid represented by arrows 2522 is transferred through manifold2528 and divided into three streams in three conduit branches, 2538,2544, and 2552, represented by arrows 2540, 2542, 2554.

Referring to circular cross section A-A, in the lower section, particles2502 higher in lean content stratify by sedimentation, whereas theparticles 2556 higher in fat content are stratified at the upper innerside of the circular conduit, which are the lighter, less denseparticles. At the central section 2558, the density of particlessuspended in the fluid is between the upper and lower extremes. Asstream 2522 travels under controlled positive displacement pump flow,the manifold profile gradually changes and at cross section B-Brepresented by member 2510, stratified suspended particles are shown tobe located at the upper 2562 and lower 2566 extremes with space 2564generally containing few particles. As the profile changes movingfurther down the manifold 2528 to the cross section 2512, the lightparticles 2568 located at the upper extreme of manifold 2528 are nowfurther away from the denser particles 2572 which are located at thelower end of the elongated cross section. Cross section D-D shows evengreater separation of the lighter particles 2578 in the upper section2516 from the more dense particles in the low section at 2574 withmiddle section 2576 carrying the least accumulation of particles.

A pump is attached to the conduit 2538. The mass flow of fluid withsuspended particles extracted in the direction shown by arrows 2540within conduit branch 2538 is controlled by the positive displacementpump driven by variable frequency drive speed control. Similarly apositive displacement pump is attached to conduit branch 2544 so as tocontrol mass flow of the fluid with suspended particles passing throughconduit 2544 in the direction shown by arrows 2542. It is not necessaryto install a positive displacement pump attached at conduit branch 2552since the flow control of stream 2544 is determined by the combined flowof streams represented by arrows 2540 and 2542. By adjusting the massflow of one or both of the streams 2540, and 2542, the fat content andthe lean content of each stream can be adjusted. For example, by slowingmass flow through conduit branch 2538, fat content in the lower streamswill increase, and by increasing mass flow through conduit 2538, the fatcontent of the lower streams shown by 2542 and 2554 will be reduced.Although the embodiment just described may have mass flow control on thehigh conduit branch 2538 and the middle conduit branch 2544, the pump oneither can be omitted and placed on the lower conduit branch 2552. Ingeneral, for X number of conduit branches, X−1 pumps can be used tocontrol the flow of all conduit branches, so that the flow through theconduit branch without a pump, is controlled as a result of control ofthe other flows.

Embodiment 6

Referring to FIG. 10, an embodiment of a separation manifold 1970 isillustrated. The separation manifold 1970 can be used as the separatorblock 30 mentioned in association with FIG. 1. The separation manifoldillustrated in FIG. 10 may be substituted for any of the previousembodiments of separation manifolds illustrated in FIGS. 2, 3, 4, 6, 7,8, and 9. The separation manifold 1970 includes that portion of themanifold that receives an inlet fluid comprising fat particles and leanparticles and produces at least two fluid streams, respectively of highfat and high lean content. One fluid stream includes essentially fatparticles, while the second fluid stream includes lean particles and agenerally desired content of fat particles so that the majority of theparticles are lean particles. The remaining solids are determined toresult in a desired concentration of fat.

In FIG. 10, the inlet fluid stream 1900, shown as arrows, enters inlet1902. The fluid 1900 includes fat particles and lean particles in afluid mixture. The fluid passes through an interior centrally disposednozzle 1986, which outlets at 1984. The purpose of nozzle 1986 will bedescribed further below. In one embodiment, as the inlet fluid passesthe nozzle 1986, the manifold enters a convergent section 1946. In theconvergent section 1946, the diameter of the inlet 1902 can reduce to asmaller diameter, which has the effect of increasing the speed of theinlet fluid 1980 together with the fluid 1982 exiting the nozzle 1986.After entering the convergent section 1946 and passing into the smalldiameter of the convergent section 1946, the separation manifold may beconstructed from a block 1970.

Block 1970, the separation manifold, can be described as follows. Fromthe small diameter following the convergent section 1946, the separationmanifold expands in diameter. At its greatest diameter, the manifoldbranches into four distinct separate conduits. The separation manifoldgradually expands in diameter to reach a maximum diameter. At orapproximately at the largest diameter, the separation manifold branchesinto four conduit branches, each conduit branch being a smaller diameterthan the maximum diameter prior to the conduit branches. The firstconduit branch 1964 is highest in elevation, and as described before,the highest elevation of the fluid contains substantially all fatparticles, denoted by arrow 1956. The fluid that is drawn into branchconduit 1964 enters pump 1966, which transfers the fluid and fatparticles denoted as arrow 1968 to the fat/liquid separation, block 48,illustrated in FIG. 1. The lowest elevation conduit branch 1910 carriesa majority of lean particles and may further carry a desired proportionof fat particles. The lowest conduit branch 1910 does not have a pumpand exits through outlet 1912 and the fluid with the majority of leanparticles and a desired or minor proportion of fat solid particles 1914can be transferred to liquid/separation, block 42 illustrated in FIG. 1.Two middle conduits, respectively 1928 and 1962, are intermediate inelevation between the high elevation conduit branch 1964 and the lowelevation conduit branch 1910. The middle branch conduits 1962 and 1928rejoin each other at the inlet for pump 1922. Upper middle branch 1962and lower middle branch 1928 essentially collect fluid with minimalsolid matter from the central portion of the manifold. From pump 1922,the fluid is transferred through pump outlet 1920 and then into coriolismeasuring instrument 1916 and to conduit 1906. The fluid then entersdevice 1904, which is generally an emulsifier of fat that furtherseparates any remaining fat from connective tissue. Following emulsifier1904, the fluid is injected in the middle of the inlet stream 1900. Theemulsification of any fat and connective tissue allows for theseparation and collection of additional fat.

The separation manifold 1970 includes a divider 1942 placed in the pathof the stream at 1978. The divider 1942 includes an injection port 1940,which injects clear fluid, denoted by arrows 1938 into the separationmanifold and with the direction of flow of the fluid. The divider 1942may have a singular point at the proximal edge and two distal points atthe distal end, appearing to be two mirror image chevrons. Clear fluidis dispensed between the distal points and with the flow of the fluid.The clear fluid will generally flow into the upper and lower middleconduit branches 1962 and 1928. The clear fluid provides a layer offluid that allows any fat that gets entrained in the lower section ofthe separation manifold to migrate through the clear fluid in the centerof the stream in the direction shown by arrow 1932, and to combine withthe fat particles flowing in the direction of arrow 1972 to enter intothe higher elevation conduit 1964. Similarly, any lean particles thatbecome entrained and are transferred in the flow stream above thedivider 1942 will migrate across the clear fluid stream in the directionof arrow 1974 to rejoin the essentially all-lean stream 1930 and exitthrough the lower branch conduit 1910. The fat particles that areentrained in the flow below the divider 1942 will cross the clear fluidboundary layer and rejoin the flow of essentially all fat particles 1972and exit through the higher branch conduit 1964.

As can be appreciated there is one inlet stream to manifold 1970 and twooutlet streams. A measuring instrument from which it is possible todetermine the fat content of a stream, such as a coriolis measuringinstrument, may be placed inline on the conduit 1968 from pump 1966, andon conduit 1912. The speed of the pump 1966 can control the amount offat that leaves with the lean solid particles through conduit 1910. Forexample, by slowing the pump 1966, more fat will enter the lean streamand leave through lower conduit branch 1912. Conversely, speeding up thepump 1966 will withdraw more fat from the system thus leaving less fatto exit with the lean particle stream 1910 through lower conduit branch1912. As can be appreciated the fat content of the flow through conduit1912 may be controlled to produce a product having a desired fatcontent.

Embodiment 7

Referring to FIG. 16, another embodiment of a conduit used as a manifoldseparator 3100 is illustrated. The manifold separator 3100 may be usedas the separation block 30 in the method illustrated in FIG. 1. Themanifold separator 3100 comprises a “triangular” shaped chamber definedby sides 3153 at the upper right, 3133 at the lower right and 3143 atthe upper left, and has a rectangular cross section and is about 6inches deep. The separator 3100 is configured such that a corner wherethe sides 3153 and 3143 meet is positioned to be the highest inelevation.

Ports are also provided at each lower corner. Thin gauge plates such as3142, 3144, 3140, 3162 are fixed in a vertical disposition across theflat front and flat back of the separator chamber. The vertical platesare spaced apart so as to restrict fluid and suspended solids movementto a vertical direction such as shown by arrow 3160. The vertical platesallow spaces between the plates and the three sides 3153, 3133, and3143, so that fluid and lean and fat matter can be carried therethrough.Conduit 3110 is the entry conduit for a “slurry” of treated beefparticles (having been chilled, transferred through the bond breakingdevice (block 12 of FIG. 1) and mixed with a measured (minimized)quantity of fluid such as carbonic acid or water etc) in direction ofarrow 3106. Jets of more temperature controlled fluid are transferredinto space 3119 via ports 3113 and 3117. Lighter fat particles willseparate and move upwards or float in the direction shown by arrows3120, 3122, 3126, while heavier lean particles will sink in thedirection shown by arrows 3124, 3128, 3130 and will collect in conduits3133, 3132 in direction shown by arrows 3134.

Excess fluid is extracted via a port 3136 in the direction shown byarrow 3138. Input and output streams may be mass flow controlled bypumps such as WAUKESHA 3152, and 3192. Coriolis measuring instrument3100 and homogenizing member 3102 are arranged to measure and treat thefat and lean stream transferred through conduit 3198, 3196 in thedirection shown by narrows 3194, 3104 and mass flow controlled accordingto a “balanced” input and output control system. Fat stream representedby stream 3190 is flow controlled by Waukesha pump 3152 via port 3148.

The embodiment of FIG. 16 can minimize the amount of fluid required byproviding adequate fluid at the place of separation only. For example,very little fluid will leave with the fat stream represented by arrow3196.

Embodiment 8

Referring to FIGS. 17A-17B, a method and an apparatus for pathogendeactivation combined with separation are illustrated.

First and second vessels, 220 and 222, of similar capacity are arrangedin parallel at close proximity and at a common height. A single directconnection between the vessels 220, 222, is located at the highestaltitude in each vessel and comprises a horizontal conduit 218 with avalve 216 centrally located. The conduit 218 communicates at each endvia a single port with each of the first 220 and second 222 vessels.

Both first 220 and second 222 vessels have a large diameter, and upperand lower ports. Vessel 220 has upper port 240 and lower port 230.Vessel 222 has upper port 226 and lower port 224. Each port is fittedwith a suitable valve. Each port is located at opposite sides of thefirst and second vessels with a first centrally located along the upperridge of the vessel and a second along the lower ridge of the vessel.

Each vessel 220 and 222 has a first and second piston. For example,vessel 220 has pistons 208 and 210. Vessel 222 is similarly fitted withtwo pistons. Each of the first and second pistons are attached to firstand second piston rods with each piston fitted into opposing ends ofeach vessel. Suitably sized and mounted hydraulic cylinders are arrangedto drive each piston independently or simultaneously toward or away fromthe perpendicular centerline of each first 220 and second 222 vessels.

Diced beef is chilled and treated to break the friable fat away from thelean matter as described above, and the beef pieces 201 comprising leanparticles and fat particles are loaded into a feed hopper 204 via port202. The first vessel 220 is then filled through port 240 to about 50%of vessel's 220 internal volume and the remaining space is then filledwith liquid carbon dioxide 212 through port 230 and pressurized to 495psia+/−2 psia.

The second vessel 222 is filled with carbon dioxide vapor at 495 psiaand connected directly, via conduit 218, with the space 232 of the firstvessel 220 above the beef pieces 228 and in such a way as to ensureconstant (equal) pressure in first 220 and second 222 vessels.

At greater than 400 psia and 18° F. (density of carbon dioxide is 60.20lbs/cubic foot) and less than 536 psia at 36° F. (density of carbondioxide is 56.92 lbs/cubic foot) and most preferably at between 490 psiaat 30° F. (density of carbon dioxide is 58 lbs/cubic foot) and at 505psia at 32° F. (density of carbon dioxide is 57.77 lbs/cubic foot). Thedensity of beef fat and beef lean, held at a temperature ranging between18° F. to 36° F. is about 55 lbs./cubic foot to 56 lbs./cubic foot forfat and between about 60 lbs./cubic foot and 66 lbs./cubic foot for leanbeef and between 29.5° F. to 32° F. about 55 lbs./cubic foot for fat and66 lbs./cubic foot for lean beef (i.e., above temperature of frozenwater) lean has a density of about 66 lbs/cubic foot.

The contents of the first vessel 220 is then agitated gently, so as toenable the buoyant fat 246 to float and the heavier lean 244 to sink,steadily, as seen in FIG. 17B. The valve 216 on conduit 218 is thenopened and the pistons 208, 210 in the first vessel 220 are closedtogether until the buoyant fat 246, having accumulated along theuppermost level along the inside of the vessel 220, is transferredthrough connecting conduit 218 to second vessel 222, as seen in FIG.17B.

DENSITY (LBS/CU′) AT SPECIFIED H2O TEMPERATURE CONTENT Matter 18° F. 36°F. LBS/CU′ 29.5° 32° F.  15% Fat 56 55 LBS/CU′ 55 55  73% Lean 60 66LBS/CU′ 66 66 100% Water 57.41 62.4 LBS/CU′ 62.4 100% Ice 57.41 LBS/CU′57.41

All 4 pistons (2 in each vessel) may also be activated to expand andcontract the space within both vessels and compress contents of firstand second vessels to elevate carbon dioxide pressure to above thecritical pressure and temperature of carbon dioxide. Supercriticalcarbon dioxide can be used reduce the activity of any microorganisms arepresent on the lean or fat matter. The pressure within vessels 220 and222 can be cycled between a low and higher pressure exceeding thecritical pressure and temperature a plurality of times until themicroorganisms are reduced to an acceptable level.

After transfer of the fat matter 246 to the second vessel 222, andoptionally performance of cycling between a low pressure/temperature anda high pressure above the critical pressure and temperature of carbondioxide, the pistons in each of the respective vessels 220 and 222 cancompress to separate carbon dioxide fluid from the lean matter in vessel220 and from the fat matter in vessel 222.

As can be appreciated from the description of the separators describedabove, the separators described above may be used in a method forseparating lean from fat. The method includes transferring a mixture,the mixture comprising lean particles comprising frozen water, fatparticles, and a fluid, through a conduit, allowing the frozen water inthe lean particles to thaw as the mixture travels through the conduitand increases the density of the lean particles, accumulating the leanparticles with non-frozen water at a first elevation in the conduit andaccumulating fat particles at a second elevation in the conduit, whereinthe first elevation is lower than the second elevation, and transferringa portion of the mixture having the accumulated lean particles through afirst conduit branch connected to the conduit, wherein the portion ofthe mixture transferred in the first conduit branch has a majority ofthe lean particles in the mixture. This method further includesadditional features and steps as step forth below and as described inthe embodiments that follow.

In one embodiment, the method may further include transferring a secondportion of the mixture having the accumulated fat particles through asecond conduit branch connected to the conduit, wherein the mixture inthe second conduit branch comprises a greater percent by weight of fatparticles compared to the mixture in the first conduit branch.

In one embodiment, the method may further include transferring a thirdportion of the mixture through a third conduit branch connected to theconduit, wherein the mixture in the third conduit branch comprises agreater percent by weight of fluid than fat and lean.

In one embodiment, the method may further include, wherein the leanparticles and the fat particles in the mixture in the conduit prior tothawing of the frozen water have a substantially similar density thatprevents the lean particles and the fat particles from accumulating atdifferent elevations.

In one embodiment, the method may further include adding carbonic acidsolution to the mixture before step (a), wherein the carbonic acidsolution has a temperature higher than the freezing point of water tothaw the frozen water.

In one embodiment, the method may further include, wherein the mixturecomprises bones, and allowing the bones to separate from the mixturebefore the thawing of water.

In one embodiment, the method may further include, wherein the conduitcomprises a vertical section and a horizontal section, and bones areseparated at a bend from the vertical section to the horizontal section.

In one embodiment, the method may further include, wherein the conduitcomprises a vertical section and a horizontal section, and carbonic acidsolution is added at a point in the vertical section.

In one embodiment, the method may further include, wherein the conduitcomprises a vertical section and a horizontal section, and a hopper isconnected to an upper end of the vertical section, and carbon dioxidegas is added to the vertical section above the point where the carbonicacid solution is added to prevent carbonic acid solution from enteringthe hopper.

In one embodiment, the method may further include providing a valve atthe bottom of the hopper, and the valve is opened to allow apredetermined amount of mixture into the vertical section.

In one embodiment, the method may further include, before step (a),crushing beef particles comprising both fat matter and lean matter toproduce the lean particles and the fat particles in the mixture.

In one embodiment, the method may further include before crushing beefparticles comprising both fat matter and lean matter to produce the leanparticles and the fat particles in the mixture, chilling the beefparticles to a temperature at which the fat matter can crumble andseparate from the lean matter to produce fat particles and leanparticles.

In one embodiment, the method may further include, wherein the amount offluid by weight is at least equal to or greater than the combined weightof fat particles and lean particles.

In one embodiment, the method may further include transferring a thirdportion of the mixture through a third conduit branch connected to theconduit, wherein the mixture in the third conduit branch comprises agreater percent by weight of fluid than fat and lean, wherein the thirdconduit branch is higher in elevation than the first conduit branch.

In one embodiment, the method may further include transferring a secondportion of the mixture having the accumulated fat particles through asecond conduit branch connected to the conduit, wherein the mixture inthe second conduit branch comprises a greater percent by weight of fatparticles compared to the mixture in the first conduit branch, andtransferring a third portion of the mixture through a third conduitbranch connected to the conduit, wherein the third conduit branchdivides into an upper branch to connect with the first conduit branch,and a lower branch to connect with the second conduit branch.

In one embodiment, the method may further include transferring a secondportion of the mixture having the accumulated fat particles through asecond conduit branch connected to the conduit, wherein the mixture inthe second conduit branch comprises a greater percent by weight of fatparticles compared to the mixture in the first conduit branch; andemulsifying the second portion of the mixture and transferring theemulsified mixture through a lower and upper branch conduits, whereinthe lower branch conduit connects to the first conduit branch.

In one embodiment, the method may further include transferring theemulsified mixture through a lower, center and upper branch conduits,wherein the lower branch conduit connects with the first conduit branch,the center branch conduit connects with the upper branch conduit and thefirst conduit.

In one embodiment, the method may further include separating fluid fromthe portion of the mixture having the accumulated lean particles viacentrifugation.

In one embodiment, the method may further include transferring a secondportion of the mixture having the accumulated fat particles through asecond conduit branch connected to the conduit, wherein the mixture inthe second conduit branch comprises a greater percent by weight of fatparticles compared to the mixture in the first conduit branch; andseparating fluid from the second portion of the mixture having theaccumulated fat particles via centrifugation.

In one embodiment, the method may further include transferring a secondportion of the mixture having the accumulated fat particles through asecond conduit branch connected to the conduit, wherein the mixture inthe second conduit branch comprises a greater percent by weight of fatparticles compared to the mixture in the first conduit branch; andallowing fluid and fat particles from the second portion of the mixtureto stratify within a vessel to produce a stratum comprising a majorityof fat particles and a stratum comprising a majority of fluid. Thismethod may further include collecting the stratified fat particles. Thismethod may further include, wherein the fluid comprises carbonic acid,and further comprising collecting the stratified fluid with carbonicacid and heating the fluid to produce carbon dioxide gas. This methodmay further include collecting lean particles that stratify at thebottom of the vessel, and returning the lean particles to the mixture ofstep (a).

In one embodiment, the method may further include, wherein the portionof the mixture transferred in the first conduit comprises a minority ofthe fat particles in the mixture. This method may further include,wherein the second portion of the mixture transferred in the secondconduit comprises a minority of the lean particles in the mixture.

In one embodiment, the method may further include, wherein the conduitcomprises a chamber having a triangular shape with three sides, a cornerof the chamber formed by two of the sides is at a first high elevation,and the chamber includes plates defining passages leading from a lowerelevation of the chamber to the first high elevation. This method mayfurther include, wherein the triangular chamber comprises at least twoexterior sides that are not horizontal and not vertical with respect toa ground surface.

In one embodiment, the method may further include providing a pluralityof horizontal plates in the conduit, wherein a horizontal platecomprises a proximal end that terminates further upstream in the conduitas compared to a proximal end of a horizontal plate of lower elevation.

In one embodiment, the method may further include providing a secondbranch conduit connected to the conduit at a higher elevation than thefirst branch conduit, providing a third branch conduit connected to theconduit at a higher elevation than the second branch conduit, providinga plurality of horizontal plates in the conduit, and juxtaposing aproximal end of a dividing plate next to a distal end of a horizontalplate, and transferring a portion of the mixture below the dividingplate to the second branch conduit, and transferring a portion of themixture above the dividing plate to the third branch conduit, whereinthe percent of fat by weight of the mixture in the third conduit ishigher than the percent fat by weight of the mixture in the secondconduit. This method may further include, wherein the distal ends of thehorizontal plates define an arc, and the dividing plate is pivotable tojuxtapose a proximal end of the dividing plate next to a distal end of ahorizontal plate. This method may further include providing a stationarydividing plate between the second and third conduits, wherein the lowersurface of the dividing plate leads to the second branch conduit, andthe upper surface of the dividing plate leads to the third branchconduit, and the pivoting dividing plate is proximally located to thestationary dividing plate.

In one embodiment, the method may further include, wherein the conduithas an aspect ratio defined as the cross-sectional width divided by thecross-sectional height, and the aspect ratio decreases along the lengthof the conduit from a proximal side to a distal side.

A method for separating fat matter from lean matter includestransferring a mixture, the mixture comprising lean particles comprisingfrozen water, fat particles, and a fluid, through a conduit, allowingthe frozen water in the lean particles to thaw as the mixture travelsthrough the conduit and increases the density of the lean particles,accumulating the fat particles at a first elevation in the conduit andaccumulating the lean particles with nonfrozen water at a secondelevation in the conduit, wherein the first elevation is higher than thesecond elevation, and transferring a portion of the mixture having theaccumulated fat particles through a first conduit branch connected tothe conduit, wherein the portion of the mixture transferred in the firstconduit branch has a majority of the fat particles in the mixture. Thismethod may further include transferring a second portion of the mixturethrough a second branch conduit that connects to the first conduitbranch, and the second branch conduit is higher in elevation than thefirst branch conduit, and includes a greater percentage of fat matter ascompared to fat matter in the first conduit branch.

One embodiment of a method is related to a method for separating leanfrom fat. The method includes: (a) transferring a mixture through aconduit, wherein the mixture comprises lean particles with frozen water,fat particles, and a fluid; (b) allowing the frozen water in the leanparticles to thaw as the mixture travels through the conduit, andincreases a density of the lean particles; (c) accumulating the leanparticles with non-frozen water at a first elevation in the conduit, andaccumulating fat particles at a second elevation in the conduit, whereinthe first elevation is lower than the second elevation.

In one embodiment, the method may further comprise transferring theaccumulated lean particles through a conduit branch connected to theconduit, wherein the accumulated lean particles transferred in theconduit branch comprise a majority of the lean particles in the mixture.

In one embodiment, the method may further comprise transferring theaccumulated fat particles through a conduit branch connected to theconduit, wherein the accumulated fat particles transferred in the secondconduit branch comprise a majority of the fat particles in the mixture.

In one embodiment, the method may further comprise transferring aportion of the mixture through a conduit branch connected to theconduit, wherein the mixture in the conduit branch comprises a greaterpercent by weight of fluid than fat and lean.

In one embodiment, the lean particles and the fat particles in themixture in the conduit prior to thawing of the frozen water have asubstantially similar density that prevents the lean particles and thefat particles from accumulating at different elevations.

In one embodiment, the method may further comprise adding carbonic acidsolution to the mixture before step (a).

In one embodiment, the fluid may have a temperature higher than thefreezing point of water.

In one embodiment, the mixture may further comprise bones, and allowingthe bones to separate from the mixture before the thawing of water.

In one embodiment, the conduit may comprise a vertical section and ahorizontal section, and the bones are separated at a bend from thevertical section to the horizontal section.

In one embodiment, the method may further comprise, before step (a),applying pressure to pieces of beef comprising both fat matter and leanmatter to produce the lean particles and the fat particles in themixture.

In one embodiment, the method may further comprise, before applyingpressure, chilling the pieces of beef to a temperature at which the fatmatter becomes brittle and can crumble and separate from the lean matterupon the application of pressure.

In one embodiment, the method further comprises emulsifying theaccumulated fat particles.

In one embodiment, the method may further comprise collecting theaccumulated lean particles and centrifuging the lean particles toseparate fluid.

In one embodiment, the conduit can have an aspect ratio defined as thecross-sectional width divided by the cross-sectional height, and theaspect ratio decreases along the length of the conduit from a proximalside to a distal side.

When the separators include coriolis measuring instructions that areused to control the massflow via a flow controlled pump, such asgenerally illustrated in FIG. 3, the separators may be used in a methodto achieve a product having a predetermined fat content of the leanstream (i.e., blocks 42, 44, and 56 of FIG. 1). Accordingly, theseparators may be used in a method for producing a beef product having apredetermined fat content, including: (a) transferring a mixturecomprising measured proportions of a first stream of lean and fatparticles with a second stream of fluid, through a conduit; (b)transferring a first portion of the mixture having accumulated leanparticles through a first conduit branch connected to the conduit,wherein the portion of the mixture transferred in the first conduitbranch has a majority of the lean particles in the mixture; (c)transferring a second portion of the mixture having accumulated fatparticles through a second conduit branch connected to the conduit,wherein the portion of the mixture transferred in the second conduitbranch has a majority of the fat particles in the mixture; (d) measuringthe first portion of the mixture having the accumulated lean particlesin the first conduit branch and determining the content of fat in thefirst portion; (e) comparing the content of fat in the first portionwith a target fat content, and further performing (f1) or (f2), wherein(f1) is increasing the massflow of the second portion of the mixturethrough the second conduit branch to decrease the fat content of thefirst portion of the mixture in the first conduit branch, and (f2) isdecreasing the massflow of the second portion of mixture through thesecond conduit branch to increase the fat content of the first portionof the mixture in the first conduit branch.

In one embodiment, the method may further include measuring the massflowof the first portion of the mixture and determining a density, andcorrelating a density to the fat content of the first portion of themixture.

In one embodiment obtaining a plurality of measurements of the massflowof the first portion of the mixture, and obtaining an average of themeasurements.

In one embodiment, the method may further include reducing the mass flowof the second stream of the mixture flowing through the second conduitbranch and maintaining a constant mass-flow until the fat content of thefirst stream of the mixture reaches a high target value, and thenincreasing the mass-flow of the second portion of the mixture throughthe second conduit branch and maintaining a constant massflow until thefat content of the first portion of the mixture reaches a low targetvalue, wherein the high target value and the low target value are notthe same. This method may further include measuring the fat content ofthe second portion of the mixture and determining the constant massflowbased on the measured fat content of the second portion of the mixture.

In one embodiment, the method may further include separating the mixtureinto three portions, wherein the third portion is lower in fat contentthan the second portion.

Fat Emulsifier

Referring to FIG. 11, an emulsifying device is illustrated. The deviceincludes an inlet 2102 and an outlet 2152. Between the inlet 2102 andthe outlet 2152, a high shear-producing member is placed in the path offluid carrying particles comprising fat. The fluid stream comprising fatparticles, denoted by arrow 2100, is introduced through the inlet 2102.A cone-shaped plug 2156 fits within a cylinder. The plug 2156 rests on apiston 2122 that is located at the bottom of the chamber. The piston2122 includes piston rings 2120, which provide sealing around thecylinder walls 2116. Thus, the piston with the cone-shaped plug 2156 canbe moved upwards and downwards within the cylinder 2116. An annularmember 2104 creates the inlet 2102 of a specific diameter. The annularmember terminates at a lower end in a 90 degree edge that approaches,but does not touch the circumference of the cone-shaped plug 2156. Thecone-shaped plug 2156 has a diameter at its base that is larger thanthat the diameter of the inlet 2102. The cone-shaped plug 2156 tapers asit rises within the inlet of the annular member to the apex of thecone-shaped plug 2156. Furthermore, the base of the cone-shaped plug2156 may be encircled by a depression 2114. Therefore, as can beappreciated, the piston 2122 and therefore the cone-shaped plug 2156 cancreate an annular space between the circumference of the plug 2156 andthe lower edge of the annular member 2104. If the plug 2156 is broughtsufficiently close to the lower edge of the annular member 2104, a verynarrow annular space is created between the cone-shaped plug 2156 andthe lower edge. As such, the velocity is increased and very high shearforces will cause any fat to be scraped or removed from the larger solidparticles. The plug 2156 can be moved up or down to change the width ofthe annular space, and thus, also create a small or large pressure dropin passing the shear zone.

After passing the shear zone, the solid fat particles travel in thespace 2113 around the cone 2156 and eventually exit through the outlet2154. In this manner, as can be seen, a high-pressure will result in theemulsification of fat from solid particles.

Referring to FIG. 12, a second embodiment of a fat emulsifier isillustrated. The fat emulsifier is incorporated into a conduit 2910 ofgenerally rectangular configuration. The inlet 2904 is for transferringa mixture of fluid, solid, fat and lean particles, denoted by arrows2900. From the inlet 2904, the conduit 2910 rapidly increases indiameter. This rapid increase in diameter allows fat particles to flowupward, while the lean particles flow downward. The lean particles 2908follow a path along the lower section of conduit 2910 due to the higherdensity, while the fat particles 2958 generally flow upward andencounter a diverter 2970. The stationary or movable diverter 2970 ispositioned between a first outlet conduit 2952 and a second inletconduit 2940. The diverter 2970 includes a wide base connected to anarrow stem on top. The diverter 2970 projects downward from the top ofthe conduit 2910, such that a sharp edge of the diverter 2970 is facingin the direction of the oncoming fluid 2958, 2956 and the edge directsthe uppermost fluid to enter the conduit 2952. The diverter 2970 may beraised to create a narrow gap 2954. Such narrowing of the gap 2954,increases the pressure drop and creates higher shear forces on anyparticles passing through the gap 2954, which provides for a way ofseparating fat from connective tissue.

The fluid with the entrained solid fat particles, which have now beensubjected to high shear forces, are diverted by the plug 2970 into theinlet conduit 2952 and are then directed to a pump (not shown), whichthen returns the fluid through conduit 2940 into the conduit 2910. Thepump returns the mixture of fluid and fat particles through the inletnozzle 2940 on the distal side of the diverter 2970.

Compared to the diameter of the inlet conduit 2904, the diameter of theconduit 2910 is relatively three-fold, and this causes the fluid carriedin the center of the conduit 2910 to be essentially clear fluid. Theclear fluid allows the materials separated from the fat and which areheavier than the fat to immediately sink after exiting the distal sideof the diverter 2970 through conduit 2940. The conduit 2910 has twodistal outlets. The higher elevation conduit branch 2926 will remove amixture of fluid with fat particles 2930. The lower conduit branch 2920will remove fluid with lean particles 2922 and any particles that havebeen stripped from the fat particles. Such particles that werepreviously attached with fat are shown as arrows 2932 and 2934traversing downward across the clear fluid that fills the center 2912 ofthe conduit 2910 and are directed toward the lower conduit branch 2920.

It should be noted that the end piece 2924 of conduit 2910 has a convexinterior shape that assists with directing flow to both high conduitbranch 2926 and low conduit branch 2920.

Bond Breaking Compression Device

FIG. 13A shows the end view of a pair of rollers that may be used in oneembodiment of the bond breaking compression device, block 12 of FIG. 1.A pair of shafts 5020 and 5010 are mounted in bearings (not shown) witha timing belt drive arranged to rotate roller 5022 and 5016 in oppositedirections with roller 5016 rotating in a counter clockwise directionwhile 5022 rotates in a clockwise direction. Rollers 5016 and 5022 arepositioned relative to each other such that diced andtemperature-reduced beef product as described earlier can be transferredthere between in the direction shown by arrows 5016 and 5014. Thedistance between the perpendicular centerline of each roller is held ina selected position such that protrusions 5015 and recess 5012 areadjacent to each other as the rollers rotate and provide a gap 5026, asshown in FIG. 13B of a hypothetical condition, wherein the surface ofeach roller has been straightened and the recess 5008 and protrusion5004 are arranged opposite to the other roller such that the protrusionis opposite a recess.

The length of the protrusion 5004 is less than the length of the recess5008 such that when the distance between the rollers 5016 and 5022 is asshown, a clamping force can be applied to the beef pieces transferredtherebetween but no damage such as cutting the beef occurs. All cornersare radiused heavily and this further limits the capacity of the rollersto damage the beef product by cutting while performing crushing toliberate the friable fat matter from the beef pieces, leaving mostlylean matter and little fat matter on the beef pieces.

The temperature of the individual beef pieces is controlled such thatthe lean matter of the beef piece will remain flexible and not be proneto breakage or shattering, while the fat matter is friable and prone tobreakage and will fracture and shatter into small particles. In oneembodiment, the bond breaking compression device includes intermeshingteeth, either on opposed rollers, as just described in associate withFIG. 13A, or on top and bottom threads running parallel in a continuousmanner. The spacing of the teeth can be determined based on the size ofthe fat particles that are shattered coming from the outlet of the bondbreaking compression device. If the fat particles are too large, thespacing between the teeth can be decreased to reduce the size of fatparticles. If the fat particles are too small and/or lean is combinedwith the fat, then the spacing of the intermeshing teeth can beincreased. From the bond breaking compression device approximately 1,000lbs., for example, can be accumulated in a storage hopper and at theappropriate cycle time transferred to separation equipment, wherein thebeef and fat particles are blended with a quantity of carbonic acidsufficient to fill the separation equipment which is sealed andpressurized to approximately 150 psia prior to the carbonic acid fluidtransfer therein.

As can be appreciated from the description above, the bond breakingdevice of FIGS. 13A and 13B, may be used in a method for separatingsolid fat from beef pieces.

The method includes (a) chilling beef pieces comprising fat matter andlean matter for a time and at a temperature that results in unevenchilling of surfaces of the fat matter and lean matter, wherein the leanmatter is chilled to a temperature to cause freezing of water in thelean matter, and the surface temperature of the fat matter is lower thanthe surface temperature of the lean matter, and (b) applying pressure tothe beef pieces to break the fat matter from the beef pieces whileleaving the lean matter intact.

In one embodiment, the method may further include, wherein in step (b)the surface temperature of the fat matter is lower than the surfacetemperature of the lean matter by at least 5° F.

In one embodiment, the method may further include, wherein in step (b),the surface temperature of the lean matter is 26° F. or less, and thesurface temperature of the fat matter is 5° F. or greater, and thesurface temperature of the fat matter is lower than the surfacetemperature of the lean matter.

In one embodiment, the method may further include passing the beefpieces between a pair of parallel, adjacent, non contacting, drivenrollers, each roller having alternating recesses and protrusions aroundthe perimeter, wherein the rollers are arranged to position a recess ofone roller opposite to a protrusion of the second roller, without therollers being in contact.

Selected Fat Content

FIG. 14 shows a front elevation of an assembly of apparatus arranged toproduce a selected fat content boneless beef product from the lean andfat streams separated in a separation system as described herein inassociation with FIGS. 2-8. The apparatus can provide for the liquidseparation from lean solid particles and fat solid particles shown asblocks 42 and 48 of FIG. 1, and further provide for the combining of fatand lean to produce a product of selected fat content represented by theblocks 42, 44, 46, 48, 50, 52, and 54. However, in other embodiments,the fat content that is present with the lean stream can be controlledvia the control of the flow rate of the fat stream, such that more orless fat can be added to the lean stream by controlling the amount offlow that is withdrawn from the system, such as described, for example,in association with FIGS. 3, 4, 6, 7, and 8.

In FIG. 1, all the mass flowing into the separation block 30 is measuredas well as the mass flow of any stream leaving the separation block.Therefore, a total mass balance can be performed around the separator.The preferred measurement instrument is a coriolis flow meter. Acoriolis flow meter is able to measure the mass flow per unit time andthe density and temperature of the fluid. From knowing the density, thevolumetric flow may also be determined. In the embodiment of FIG. 1, thetotal mass flow to the separation block 30 is measured by block 28.Also, the carbonic fluid that is added is also measured by block 26,therefore, by subtracting the mass of the carbonic fluid, the mass ofthe beef pieces, including fat and lean particles can be known. If morethan one stream is added to the inlet flow, then, every flow is measuredso that the mass of the combined lean and fat particles can be known.The separation block 30 has at least two outlet flows, including thelean matter with fluid, block 32 and the fat matter with fluid, block36. However, if additional flows, such as illustrated in FIGS. 6 and 8are present, then all outlet flows are measured. All inlet or outletflows are measured to determine the mass flow, density and temperature.In FIG. 1, the bone matter and fluid flow, block 34 is optional, but, ifpresent, this flow may also be measured. As discussed above, the fluiddensity influences the degree of separation between fat and lean matter.Therefore, fluid density can be related to the amount of fat with thelean matter in block 32 because it has been found that for any givenfluid density, the lean matter will contain a predictable fat content. Acorrelation table can be created that stores a relationship betweenfluid density and a corresponding amount of fat in the lean matter ofblock 32. Therefore, the density of the flow of the lean matter andfluid of block 32 can be determined. For example, prior to of each ofthe flows of blocks 32 and 36 d.

In FIG. 14, the lean stream with carbonic acid fluid is transferred inthe direction shown by arrow 6000 via conduit 6004 and through coriolismeasuring instrument 6002, from which the flow rate, water contentand/or fat content of the lean matter/fluid may be determined, andcontinuing therefrom along conduit 6070 and into centrifuge 6068 viaport 6069. In this way, the apparatus as arranged removes liquidcarbonic acid and discharges the liquid via conduit 6008 in thedirection shown by arrow 6006. The solid, lean matter is discharged viaaperture manifold 6010 onto continuous inline weighing conveyor 6016. Ashield 6080 is arranged to provide a suitable method of dividing thecontinuous stream of lean matter deposited on conveyor 6016 intoportions with spaces there between and as can be seen with portions,such as 6018, a gap is shown between them and indeed all other portions.This is provided to enable the continuous weighing of the continuousstream divided into portions with gaps by the weighing section 6016.Shield 6080 is attached to member 6062 mounted to a means of providinghorizontal movement shown by arrow 6066. The movement indicated by arrow6066 is in a horizontal plane and shield 6080 can be arranged to shieldstrips of the conveyor such that gaps are provided as required. Conveyor6016 comprises a continuous belt which extends horizontally and is heldin position by a roller at each end 6012 and 6020. In this way, thecontinuous stream of lean matter is weighed prior to transfer intoaccumulation hopper 6024 and in the direction shown by arrows 6064 and6060.

The fat stream with carbonic acid fluid separated in a separator, suchas a manifold arrangement upstream is transferred in the direction shownby arrow 6043 and into conduit 6048 and passes through coriolismeasuring instrument 6044, from which the flow rate, water and/or fatcontent of the fat/fluid may be determined, and then is transferred intocentrifuge 6046 via centrally disposed port 6050. Solid fat matter isremoved from the stream and the spent carbonic acid is discharged viaconduit 6054 in the direction shown by arrow 6072. A horizontallydisposed continuous weighing conveyor 6038 is arranged directly beneaththe discharge port of centrifuge 6046 such that a measured proportion offat matter deposited thereon is weighed as it is transferred in thedirection shown by arrow 60734. As can be seen, portions 6036 forexample are shown with a gap between them similar to the arrangementprovided on continuous weigh belt 6016.

A shield 6076 is attached to a member mounted to a means of providinghorizontal movement. The shield 6076 can be arranged to shield strips ofthe conveyor such that gaps are provided as required. Conveyor 6038comprises a continuous belt which extends horizontally and is held inposition by a roller at each end 6030 and 6040. In this way, thecontinuous stream of fat matter is weighed prior to transfer intoaccumulation hopper 6024 and in the direction shown by arrow 6076.

The flow of fat matter and flow measured via coriolis measuringinstrument 6044 is controlled such that the amount of fat weighed andtransferred into collection hopper 6024 is the amount required toprovide a selected fat content boneless beef when combined with the leanstream weighed on conveyor 6016.

Pathogen Deactivation Vessels

A vessel includes a shuttling action that provides a semi-continuousprocess wherein approximately 2,000 lbs of beef is loaded into theshuttling basket and it is then immediately transferred into theautoclave. A measured quantity of the raw beef is accumulated inautoclave or alternatively in a hopper located directly above theshuttling basket at the input end of the autoclave and in such a waythat the shuttling basket can be loaded rapidly by opening a set of“bomb” doors arranged in the base of the upper hopper, so as to providea rapid loading of the basket. The autoclave operates by processingbatches of beef product and when an amount of, for example 2,000 lbs,has been accumulated in the shuttle basket, the autoclave is closed andall air removed by displacement with carbon dioxide fluid transferredunder pressure from carbon dioxide gas vessel. After purgingsubstantially all air from autoclave, all ports are closed except forthe connection to vessel, which charges the autoclave to about 350 psiawith carbon dioxide gas. Communication with vessel is disconnected byclosing a valve, which is immediately followed with opening of valveconnection to vessel containing liquid carbon dioxide to facilitatetransfer of carbon dioxide fluid, which then fills autoclave with 950psia fluid carbon dioxide. During the transfer of carbon dioxide intoautoclave, the beef contents enclosed within the “shuttling basket” areagitated to ensure that all surfaces of every piece of beef are exposedto sufficient liquid carbon dioxide to elevate the temperature at thesurface of the beef to a preferred temperature of at least 89° F. butnot more than about 108° F. Communication with the liquid carbon dioxidesource vessel is then interrupted by disconnecting or closing of a valveimmediately prior to the immediate opening of a valve allowing transferof super critical vapor from storage vessel, while carbon dioxide isallowed to escape via conduit connection into carbon dioxide recyclevessel. In this way super critical carbon dioxide vapor is transferredto the autoclave at a pressure of approximately 1,500 psia and, with thesuitable agitation within autoclave, all beef particle surfaces arethereby exposed to the aggressive solvent properties of super criticalcarbon dioxide. Such exposure of pathogens (e.g., E. Coli. 0157:H7,salmonella, Listeria Monocytogenes and others) to super-critical carbondioxide is lethal and will cause death within a few minutes of exposure.After a period of time of up to 7 minutes, the flow of supercriticalcarbon dioxide from vessel through autoclave and into recycle vessel isshut off and autoclave depressurized to atmospheric pressure prior tothe pathogen deactivated beef being transferred directly from autoclaveto dicing machine prior to transfer to and through carbon dioxidefreezing tunnel.

Referring to FIG. 15, a pathogen deactivation vessel (PDV) 955 is shownin partial cross section. The vessel 955 described herein may be usedfor block 4 of FIG. 1. Also as described herein, the vessel 955 may alsobe used to separate carbon dioxide liquid and/or other fluids from solidmatter, such as to separate liquid from lean matter in block 42 of FIG.1 and to separate liquid from fat matter in block 48 of FIG. 1.

The vessel includes a horizontally disposed tubular vessel 923 arrangedwith end caps 910 and 997 which are held in place by “rings” 914 and936, thereby providing an adequate sealing at interfaces such as 970.The annular members 914 and 936 can be rotated to release end caps 910and 997 or alternatively rotate in the opposite direction to tighten theend caps at interface such as 970.

A pair of horizontally opposing pistons 926 and 986, each piston beingsealingly mounted within the vessel to provide an enclosed space 928.Pistons 926 and 986 are arranged with backing plates 985 and 930,respectively, attached via piston rods 925 and 937 to hydrauliccylinders 956 and 987. Each piston assembly is fixed at itscircumferential center to a piston rod 925 or 937. FIG. 15 shows thepiston rods with pistons 986 and 926, in a fully extended position,inwardly, toward the center of the pathogen deactivation vessel 955 soas to provide 3 separated spaces, 928 is the space between the pistons,space 939 is the space between the backing plate 930 and the end cap 997and space 917 is the space between backing plate 985 and the end cap910. The space 928 between pistons is connected to both spaces 939 and917 via conduits and valves. Space 928 connects to space 939 via valve924, conduit 999 and a continuation of conduit 999 which is not shown toconduit 935 on the top side of the vessel 923 that leads into space 939.Space 928 connects to space 917 via valve 924, conduit 988 and acontinuation of conduit 988 which is not shown to conduit 915 on the topside of the vessel 923 that leads into space 917.

An upper, centrally disposed port is attached to a manifold 984 withgate valve 924, which can seal the port closed as needed. Gate valve 924separates the vessel loading apparatus from manifold 984. Conduits 999and 988 connect via suitable “open/closed” valves 1000 and 1001 (notshown) directly with ports 935 and 915 respectively (connecting pipesnot shown), such that when gate valve 942 is closed and gate valve 924is open, a direct communication between the centrally located space 928with spaces 939 and 917 is provided.

The spaces 917 and 939 are used as accumulators to receive fluid at thesame or substantially the same pressure that is within space 929.Accordingly, when the pistons 926 and 986 are moved distally from aproximal position, the fluid is forced from the space 928 into one orboth of spaces 917 and 939. Before admitting fluid to either of spaces939 and 917, preferably the spaces have been pressurized to be inequilibrium with the pressure in space 928. Alternatively, instead ofthe fluid being sent to spaces 939 and 917, the fluid may be transferredto an “external” accumulator connected to the manifold conduits 999 and988 through a valve 924 located on the top of the vessel 923. Anaccumulator can be a piston accumulator. A piston accumulator is a knowndevice and may include a fluid section and a gas section with a pistonseparating the two sections. When the fluid section draws in the fluidfrom space 928, the piston compresses the gas section, which may benitrogen, for example. However, other food compatible gasses may beused. When the pressure drops in space 928, the compressed gas forcesthe piston to discharge the stored fluid. In this case, instead oftransferring the fluid to the space 928, the fluid may be transferred tothe carbon dioxide recovery block 56 as seen in FIG. 1. A suitableaccumulator can be one supplied by Hydac. As described, an accumulatorcan be the internal spaces 939 and 917 or an external accumulator.However, both have the capability of an increasing/decreasing volumespace to accommodate a corresponding change in volume as the vesselpistons 926 and 986 move together so as to keep the carbon dioxide gasat a fairly constant pressure, such as above the critical phase ofcarbon dioxide. After treating the goods to reduce pathogen populationsthat may be present with the goods, the pressure can be raised withinthe tubular vessel 923 to a first fluid pressure value by moving thehorizontally opposed pistons 926 and 986 together and reducing the spacebetween them to decrease the density of the fluid to a value lower thana density of the goods. In some embodiments, the density of the fluid isincreased. Then, the valve 924 can be opened to connect the pressurizedspace 928 to a piston accumulator and allow the relatively lighter fluidto transfer into a liquid space of the piston accumulator while thepiston accumulator increases the volume of the liquid space and thepistons located in the vessel 923 reduce the volume of the space 928containing the goods until the fluid has been transferred into theaccumulator leaving a residual quantity of fluid with the goods. Then,the valve 924 can be closed and the pistons 926 and 986 moved apart todecrease the fluid pressure within the vessel 923 to a lower secondpressure value and opening a second valve, such as valve 942, to allowtransfer of fluid into a second vessel at a lower pressure value.

A lower, centrally located port 961 is connected to extraction conduit944 via gate valve 942. A drainage pipe 945 with valve 997 is alsoprovided.

Ports 981 and 879 are also connected to space 928 via pipe 945 ormanifold 984. Valves (not shown) are provided at ports 981 and 879 toisolate the ports as needed.

A shaft 937 extends through the center of piston rods 987 and 925,pistons 986 and 926 and backing supports 930 and 985 to an end 938.Impellors 992 and 993 are diametrically opposite each other and both areattached to impellor shaft 937 and are also profiled to fit close to therecessed surfaces of the pistons 926 and 986, respectively, as they arerotated by impellor shaft 937, which is attached to a driving mechanism(not shown).

A spur gear (wheel) 931 is fixed to the outer circumference of thepathogen deactivation vessel and is arranged to engage with pinion 952which is mounted to drive shaft 953.

A “cradle” of rollers such as 940 and 948, mounted to shafts such as 941and 950, are arranged to retain the entire weight of the pathogendeactivation vessel 955 and hold the vessel captive while allowing it tobe rotated in both clockwise and counter clockwise directions by thepinion 952, which is driven via shaft 953 so as to rotate the vesselassembly 955 190 to 180 degrees from the perpendicular in acounterclockwise direction, and then 380 to 360 degrees in a clockwisedirection, and then in a counterclockwise direction, repeating the backand forth rotation during each cycle of the apparatus described inassociation with FIG. 15.

A rotary union 903 communicates directly between supply pipe 901carrying carbon dioxide liquid or vapor and piston rod 902 passageway889 and exit port 890.

Female member 922 with inner conical profile 983 is arranged to connectwith male member 919 with conical profile 982 such that when member 919is extended in the direction shown by arrow 921, the outer surface 982and inner surface 983 of member 922 contact and provide a seal in a waythat allows boneless beef to be transferred directly from a vessel (notshown) holding a single “charge” (for example 2,000 lbs) ofpredetermined quantity of boneless beef.

Member 919 can be extended so as to sealingly mate with member 922 sothat when gate valves 942 and 924 are open and valves 1000 and 1001closed (not shown), sealing contents of spaces 917 and 939 therein. Inthis way, boneless beef of a predetermined and measured quantity (in avessel mounted on load cells above pathogen deactivation vessel 955) canbe transferred from the vessel, via members 919 and 922 and throughmanifold 984 and into space 928. After transfer of a full load(“charge”) of boneless beef into space 928, gate valve 942 can beclosed, and any open space remaining within space 928 can be filled withpressurized carbon dioxide gas to a selected pressure such as 750 psivia conduit 945 and in the direction shown by arrow 948. Followingpressurizing of space 928, valves 1000 and 1001 can be opened to providean open conduit between spaces 917, 928 and 939.

Hydraulic cylinders 987 and 956 hold pistons 926 and 986 in position, asneeded, and can be activated simultaneously to move away from each other(from distal to proximal positions), thereby increasing the volume ofspace 928 and decreasing the volume of spaces 939 and 917. This actioncauses carbon dioxide fluid to be displaced and transferred into space928 from both spaces 939 and 917 via ports 915, 981, 879 and 935. Bothpistons 926 and 986 can be withdrawn as seen fit but preferably to thefullest extent thereby transferring a major portion of the fluid carbondioxide into the expanded space 928. Valves 1000, 1001 and the valvesisolating ports 981 and 879 are then closed and pistons 986 and 926activated in a direction toward each other (from proximal to distalpositions) so as to reduce the volume of space 928, increasing pressureto about 1,500 psia.

During the movement of pistons 926 and 986 toward and away from eachother, impellors 993 and 992 are rotated and pathogen deactivationvessel 955 is also rotated. The density drops from around 40 lbs/cubicfoot to 28.96 lbs/cubic foot The pressure in the vessel is thenincreased quite rapidly to about 1,500 psia to ensure the surfacetemperature of the goods is elevated to a temperature above the criticaltemperature of carbon dioxide.

In one embodiment, the pressure is first elevated. Before the pressureis elevated, the vessel 923 is charged first with carbon dioxidegas/vapor to about 500 psia and then liquid carbon dioxide to about 700psia and agitated to ensure all goods (meat/beef) surfaces arethoroughly soaked (with the liquid carbon dioxide) at a pressure andliquid density in which boneless beef (not frozen) will become somewhatbuoyant. This spaces the pieces apart when agitated. There also needs tobe space for the sudden expansion from below (about 990 psia) criticalpressure (1,072.1 psia) to above critical pressure.

In one embodiment, pistons 926 and 986 are sequentially activated tocompress the contents of space 928 and hold a pressure of 1,500 psia,thereby maintaining a pressure above the critical pressure of carbondioxide (supercritical pressure) in space 928 for a predetermined periodsuch as 85 seconds, in one embodiment, followed by a movement of pistons926 and 986 away from each other, reducing the pressure in space 928 toa subcritical pressure of 900 psia for 85 seconds.

A treatment of boneless beef can be arranged such that each alternated85 second period at 900 psi and 85 seconds at 1,500 psi can besequentially repeated in a series of alternating sub critical and supercritical carbon dioxide phase conditions and in such a way that anybacteria present on the boneless beef will be rendered none viable orkilled.

At the conclusion of the treatment (cycle), the two pistons 926 and 986move toward each other and in so doing, reduce the volume of space 928to a minimum and expand the volume in spaces 917 and 939, while stillrotating the vessel (back and forth) until the boneless beef iscompressed in the center so as to expel all carbon dioxide fluid whichis extracted via the upper manifold and into the spaces 917 or 939. Inthis way, carbon dioxide loss is substantially reduced. A furtheradvantage is to avoid the freezing of boneless beef during the removalof the fluid carbon dioxide.

The following TABLE 3 provides one embodiment of a sequence of stepsthat may be executed by the pathogen deactivation vessel 955.

TABLE 3 Sequ. Sequence/Action per single system cycle and then repeat #in a continuous succession of cycles Seconds 1 PDV Evacuation [50%] byretracting pistons—aided by 16 external blower (if needed) 2 Load 2,000lbs boneless beef = to <50% PDV volume 75 [exclude any atmosphericoxygen] 3 Pressurize PDV with vapor/gas 500 pisa to 900 psia 15 4 Closegas valves; open liquid valves, pressure to 700 psia 10 to 900 psia 5Fill with liquid carbon dioxide @ <900 psi PDV pressure 30 (from reverseside of piston) by retracting piston (additional from remote source viapiston rod) 6 Rotate PDV Thru' 1900 from perpendicular in both 85directions [additional agitation by activating pistons stroke—2 ways ×24″] and rotating impellor 7 Increase PDV pressure to 1,500 psi and <120F. 5 8 Continue rotation of PDV Thru' 190° from perpendicular 85 in bothdirections [agitation by activating pistons stroke—2 ways × 24″] plusimpellor 9 Decrease PDV pressure to 900 psi and <85 F. 5 10 Continuerotation of PDV thru' 190° from perpendicular 85 in both directions[agitation by activating pistons stroke—2 ways × 24″] plus impellor 11Increase PDV pressure to 1,500 psi and <120 F. 5 12 Continue rotation ofPDV Thru' 190° from perpendicular 85 in both directions [agitation byactivating pistons stroke—2 ways × 24″] plus impellor 13 Decrease PDVpressure to 900 psi and <85 F. 5 14 Continue rotation of PDV thru 190°from perpendicular 85 in both directions [agitation by activatingpistons stroke—2 ways × 24″] plus impellor 15 Compress beef betweenpistons to remove a pre- 70 determined quantity of carbon dioxide vaporand/or fluid from beef and transfer via an upper port (open valves to LPstorage PDVs) 16 Chill beef by sudden internal PDV pressure drop of a 75measured quantity of liquid carbon dioxide (by retracting pistons tolower pressure) and then open valve to external accumulation vessels—maybe strapped to PDV) 17 Close//open valves as required 15 18 Reduce PDVPressure to ambient (T = 32 F. to 36 F.] 45 [could be combined with 21]19 Unload beef from PDV (via lower 14″ D port) 75 20 Open/close valves10 21 Return pistons to 45% PDV volume between pistons 15 [L-carbondioxide behind pistons] CPH 4.02 3600 896.00

TABLE 4 below shows the deactivation levels using the pathogendeactivation vessel for various pressures and times.

Exposure Time After 4 Days Initial Hi Pressure Storage at Treatment -cpSC-carbon Exposure Ambient dioxide Initial Total Hi Reduc. Reduction -Pressure Log₁₀CFU/ Log₁₀CFU/ Rep # Organism PSIG Min Gm. Gm. 1 GenericE. Coli 2,400 3 1.2 4.0 2 E. Coli 0157:H7 2,100 3 1.8 3.5 3 Generic E.Coli 1,800 7 1.1 3.0 4 E. Coli 0157:H7 1,600 7 1.9 4.1 5 E. Coli 0157:H71,500 1 1.6 3.8 6 Generic E. Coli 1,300 5 0.9 2.9 7 E. Coli 0157:H71,100 5 0.8 2.9

TABLE 5 below shows the deactivation levels using the pathogendeactivation vessel for various pressures and times.

Hi Organisms Pressure Exposure Reduction Rep # (Cocktail) PSIG MinutesLog₁₀CFU/Gm. Treatment - controlled phase Super Critical carbon dioxide1 Generic E. Coli 1,100 3 5.8 E. Coli 0157:H7 to 5.7 Listeria 1,300 4.0monocytogenes Salmonella - spp. 5.8 2 Generic E. Coli 1,600 3 5.8 E.Coli 0157:H7 to 6.4 Listeria 1,800 4.7 Monocytogenes Salmonella - spp.6.0 3 Generic E. Coli 2,000 3 1.9 E. Coli 0157:H7 to 4.4 Listeria 2,200Monocytogenes 5.2 Salmonella - spp. 6.0 Treatment - Sub-Critical(Liquid) carbon dioxide 4 E. Coli 0157:H7 3 5.5 Listeria 700-800 2.7Monocytogenes Salmonella - spp. 5.4

As can be appreciated from the description of FIG. 15, the device may beused in a method for deactivating pathogens in meat. The method includestransferring meat to a vessel, wherein the vessel includes an enclosedelongated space fitted with a first and a second piston within theinterior of the space at each of two opposing ends, and the pistonsinclude a front and back side; charging the vessel with carbon dioxide;moving the first and second piston in a direction toward each other soas to reduce the volume of the space and increase the pressure withinthe space to create a super critical carbon dioxide phase in the spacecontaining the meat; holding the super critical pressure of carbondioxide for a predetermined period of time; after holding the supercritical pressure for the predetermined period of time, moving the firstand the second pistons away from each other to reduce the pressure inthe space to a subcritical pressure of carbon dioxide; holding thesubcritical pressure of carbon dioxide for a predetermined period oftime; and after holding the subcritical pressure of carbon dioxide,moving the first and second pistons in a direction toward each other soas to reduce the volume of the space while expelling the carbon dioxidefrom the space in front of the pistons to spaces created at the back ofthe pistons.

In one embodiment, the front side of the first and the second piston isfitted with an impeller that rotates as the first and second pistonsmove toward each other.

In one embodiment, the vessel includes a central longitudinal axis, andthe vessel is rotated back and forth on the axis while the first andsecond pistons move toward each other.

In one embodiment, the method may comprise performing a plurality ofsuper critical carbon dioxide phases alternating with subcritical carbondioxide phases before expelling the carbon dioxide.

In one embodiment, the super critical pressure produced is 1,500 psi orgreater.

In one embodiment, the subcritical pressure produced is 900 psi or less.

A different embodiment related to a method for inactivating pathogenspresent on goods, includes: (a) introducing into an apparatus, pieces ofbeef, and a fluid comprising water and carbon dioxide; (b) raising apressure within the apparatus above a critical pressure of carbondioxide without elevating a temperature within the apparatus above atemperature to damage the beef; and holding the pressure and temperaturefor a selected period of time; (c) reducing the pressure within theapparatus, and increasing a density of the fluid to suspend and separatethe pieces of beef in a suspension to enable surfaces of the beef to bein contact with low pH fluid to result in death of pathogenicmicroorganisms on the surfaces of the beef.

In one embodiment, the method may further comprise adjusting the densityof the fluid where the beef becomes buoyant to allow spacing apart ofbeef.

In one embodiment, the method may further include: (d) raising thepressure within the apparatus to increase the temperature at the surfaceof the goods to above freezing point of water. This method may furtherinclude repeating steps (c) and (d) in rapid succession for more thanone cycle.

In one embodiment, the method may further include adjusting the pressureof the carbon dioxide and water to form carbonic acid, having a selectedtemperature and pH, wherein the pH value is lethal to at least onemicroorganism present with the goods.

In one embodiment, the method may further include adjusting the pressureof the carbon dioxide to form Carbonic Acid having a pH less than 5,wherein due to the low pH the carbonic acid is lethal to at least onemicroorganism on the goods.

In one embodiment, the method may further include applying ultrasonicenergy to separate microorganisms from the goods and mixing the goodswithin the chamber.

In one embodiment, the method may further include, after reducing thepressure, holding while agitating, raising the pressure and temperatureof the carbon dioxide to reach supercritical conditions, and holding thesupercritical conditions for a period of time sufficient for thesupercritical carbon dioxide to be lethal to pathogens.

In one embodiment, the method may further include, wherein liquid carbondioxide is in contact with the surfaces of the goods in sufficientquantities to cause freezing of the free water in contact withmicroorganisms.

In one embodiment, the method may further include further charging theapparatus with carbon dioxide gas/vapor to about 500 psia and thenliquid carbon dioxide to about 700 psia and agitating the apparatus tosoak goods' surfaces with liquid carbon dioxide at a pressure and liquiddensity in which beef (not frozen) will become buoyant to allow spacingapart of beef pieces when agitated.

As can be appreciated from the description of FIG. 15, the device mayalso be used in a method of separating a high vapor pressure fluid frombeef, including: (a) in an apparatus comprising a vessel, and a pistondisposed within the vessel, wherein a space is provided adjacent to thepiston, adding a high vapor pressure fluid with beef in the space; and(b) moving the piston to compress the space to separate the fluid fromthe beef, wherein the fluid is compressed at a pressure to preventevaporation and freezing of the beef.

In one embodiment, the method may further include, wherein the apparatuscomprises a second piston, wherein the piston are disposed opposite toeach other, and the pistons are moved together to compress the space toseparate the fluid from the beef.

In one embodiment, the method may further include, wherein the highvapor pressure fluid does not exist as a liquid at 1 atmosphere and 20°C.

In one embodiment, the method may further include, wherein the fluid iscarbon dioxide.

In one embodiment, the method may further include, wherein the apparatusfurther comprises a space behind the piston, wherein the space in frontof and behind the piston are in communication, and the fluid istransferred to the space behind the piston during compression.

Another embodiment related to a method for separating human edible goodsfrom a pressurized fluid includes: (a) providing a horizontally disposedtubular vessel having a pair of horizontally opposed pistons, eachpiston being sealingly mounted within an end of the tubular vessel toprovide an enclosed space into which the goods and a pressurized fluidare transferred; (b) after treating the goods to reduce pathogenpopulations that may be present with the goods, raising the pressurewithin the tubular vessel to a first fluid pressure value by moving thehorizontally opposed pistons together and reducing the space betweenthem to decrease the density of the fluid to a value lower than adensity of the goods; (c) opening a first valve in a conduit connectinga pressurized space within an end of a piston accumulator to a portcentrally located on the upper side of the first vessel and allowing therelatively lighter fluid to transfer into a second space of the pistonaccumulator from the first vessel while the piston accumulator increasesthe volume of the second space and the pistons located in the firsttubular vessel reduce the volume of the space containing the goods untilthe fluid has been transferred into the accumulator leaving a residualquantity of fluid with the goods; and (d) closing the first valve andmoving the pistons apart to decrease the fluid pressure within the firstvessel to a lower second pressure value and opening a second valve toallow transfer of the fluid into a second vessel at a lower pressurevalue.

The apparatus of FIG. 15, includes: (a) a housing defining a cylindricalchamber with a first end and an opposite, second end; (b) a first pistonand a second piston disposed in a sealing manner at the opposite ends ofthe chamber so as to provide an enclosed and sealed space between thefirst and second pistons, wherein the first piston and the second pistonare driven towards one another to pressurize contents in said spacebetween the pistons to a first, high pressure and away from one anotherto depressurize contents within the space to a second, lower pressure;and (c) a mixer disposed within the housing to mix any contents betweenthe pistons.

In one embodiment, the apparatus may further include, wherein the mixerhas a piston-like member disposed in the housing, wherein thepiston-like member is in a sealing disposition with the inner surface ofthe chamber.

In one embodiment, the apparatus may further include, wherein the mixerhas a piston-like member disposed in the housing, and the piston-likemember has an opening for the passage of goods from one end of thechamber towards the other.

In one embodiment, the apparatus may further include an ultrasonicgenerator that transmits ultrasonic energy to the mixer to separatemicroorganisms from goods being processed within the chamber.

In one embodiment, the apparatus may further include, wherein the firstand the second pistons are driven by the introduction and withdrawal ofa liquid compatible with goods edible for human consumption.

In one embodiment, the apparatus may further include, wherein the mixeris configured to rotate and reciprocate in relation to the chamberlength.

In one embodiment, the apparatus may further include a first and asecond piston disposed at opposite ends of the housing to form a firstchamber and a second chamber, wherein the chambers receive a fluid todrive the first piston and the second piston.

In one embodiment, the apparatus may further include a directcommunication between a second chamber containing goods to be treatedafter transfer into the space via a port located on the upper side of,and centered on a perpendicular center-line of the chamber, such thatwhen the first and second pistons are driven away from one another, avacuum is created and the goods are thusly transferred into the space.

In one embodiment, the apparatus may further include a directcommunication between said space and a third chamber into which saidtreated goods are to be transferred via a port located on the lower sideof, and centered on a perpendicular center-line of the first chamber,such that when a vacuum is created within the third chamber and firstand second pistons are driven toward one another, the goods aretransferred into the space.

The following properties are provided for reference.

The temperature of liquid carbon dioxide at 900 psia is about 74° F.

The density of liquid carbon dioxide at 900 psia is about 45 lbs/cubicfoot.

The temperature of fluid carbon dioxide at or equal to or greater than1072.1 psia is about 87.8° F. (the Critical Temperature).

The density of fluid carbon dioxide at or equal to or greater than1072.1 psia is about 28.96 lbs/cubic foot; (the Critical Temperature).

The density just below the Critical Point, at say about 84° F. is about41 lbs/cubic foot; so it can be seen there is a substantial reduction indensity at just above The Critical Temperature, when compared to justbelow The Critical Point.

The density of the food (boneless beef), which comprises lean beef ofabout 66 lbs/cubic foot and tallow/beef-fat of about 55 lbs/cubic footand, therefore, an equal quantity of each (50's) averages about 60lbs/cubic foot to 61 lbs/cubic foot.

When boneless beef, at about 60.5 lbs/cubic foot, is immersed in fluidsupercritical carbon dioxide at about 1,100 psia, the buoyancy effect ofthe supercritical carbon dioxide, at 28.96 lbs/cubic foot (say less than30 lbs/cubic foot) is minimal when compared to liquid carbon dioxide atsay 18° F. and 400 psia, which is about equal to the average density of50's (i.e., 60.5 lbs/cubic foot).

However, the temperature of liquid carbon dioxide at 60.5 lbs/cubic footand 400 psia is about 18° F. and beef will freeze at this temperature.It is therefore useful to provide suitable temperature conditions at thesurface of the boneless beef as is pressure. A temperature of 18° F.will freeze boneless beef with any bacteria that may be present whichcould provide conditions in which at least some bacteria would bepreserved. These conditions must be avoided and therefore a compromiseis required.

It is useful that all pieces of any quantity of boneless beef beingtreated to remove or kill bacteria, or pathogens that may be present onthe beef, are thoroughly soaked and “wetted” with carbon dioxide and tosuch an extent that the entire surface of each piece including withinand under any and all slits, cracks, cuts, flaps or folds, issufficiently saturated. Most preferably, the treated surface will haveabsorbed carbon dioxide during the sub-critical treatment.

When the boneless beef is immersed in higher density, fluid carbondioxide, such that the buoyancy effect of the carbon dioxide issufficient to cause separation or the improved capacity of the beefpieces to separate, each piece of boneless beef will be more readilyexposed to the carbon dioxide in which it is immersed. When the densityof the carbon dioxide is greater, thorough soaking of all boneless beefsurfaces in the carbon dioxide is more readily provided and carbondioxide is more readily in contact with the surfaces. Under theseconditions, agitation of the combined boneless beef and fluid carbondioxide can enhance the exposure, hence the process provides for suchagitation.

More particularly, in order for the entire surfaces of the boneless beefpieces to be thoroughly soaked in fluid carbon dioxide when immersed inthe fluid carbon dioxide, greater buoyancy will more readily andthoroughly facilitate the desired exposure of all surfaces to carbondioxide and, more particularly, enable the beef surfaces to absorbrelatively greater proportions of carbon dioxide (which occurs morereadily at lower temperature). By alternating between a lower and higherpressure, carbon dioxide is absorbed at the beef surfaces at the lowertemperature, which then becomes a “source” of carbon dioxide, at thesurfaces (which is where any bacteria will be present) and provide forthe lethal conditions desired when a sudden pressure increase canprovide the desired super-critical conditions at the surfaces of theboneless beef.

In consideration of the above, a method is disclosed that providesalternating conditions of exposure to super-critical carbon dioxideconditions (which is lethal to bacteria) with sub-critical conditions,wherein pressure within the autoclave or pathogen deactivation vessel955 is sequentially and rapidly increased and decreased between about1,500 psia and about 900 psia, is disclosed.

While illustrative embodiments have been illustrated and described, itwill be appreciated that various changes can be made therein withoutdeparting from the spirit and scope of the invention.

1. A method for separating lean from fat, comprising: (a) transferring amixture through a conduit, wherein the mixture comprises lean particleswith frozen water, fat particles, and a fluid; (b) allowing the frozenwater in the lean particles to thaw as the mixture travels through theconduit, and increases a density of the lean particles; (c) accumulatingthe lean particles with non-frozen water at a first elevation in theconduit, and accumulating fat particles at a second elevation in theconduit, wherein the first elevation is lower than the second elevation.2. The method of claim 1, further comprising transferring theaccumulated lean particles through a conduit branch connected to theconduit, wherein the accumulated lean particles transferred in theconduit branch comprise a majority of the lean particles in the mixture.3. The method of claim 1, further comprising transferring theaccumulated fat particles through a conduit branch connected to theconduit, wherein the accumulated fat particles transferred in the secondconduit branch comprise a majority of the fat particles in the mixture.4. The method of claim 1, further comprising transferring a portion ofthe mixture through a conduit branch connected to the conduit, whereinthe mixture in the conduit branch comprises a greater percent by weightof fluid than fat and lean.
 5. The method of claim 1, wherein the leanparticles and the fat particles in the mixture in the conduit prior tothawing of the frozen water have a substantially similar density thatprevents the lean particles and the fat particles from accumulating atdifferent elevations.
 6. The method of claim 1, further comprisingadding carbonic acid solution to the mixture before step (a).
 7. Themethod of claim 1, wherein the fluid has a temperature higher than thefreezing point of water.
 8. The method of claim 1, wherein the mixturefurther comprises bones, and allowing the bones to separate from themixture before the thawing of water.
 9. The method of claim 8, whereinthe conduit comprises a vertical section and a horizontal section, andthe bones are separated at a bend from the vertical section to thehorizontal section.
 10. The method of claim 1, further comprising,before step (a), applying pressure to pieces of beef comprising both fatmatter and lean matter to produce the lean particles and the fatparticles in the mixture.
 11. The method of claim 10, furthercomprising, before applying pressure, chilling the pieces of beef to atemperature at which the fat matter becomes brittle and can crumble andseparate from the lean matter upon the application of pressure.
 12. Themethod of claim 1, further comprising emulsifying the accumulated fatparticles.
 13. The method of claim 1, further comprising collecting theaccumulated lean particles and centrifuging the lean particles toseparate fluid.
 14. The method of claim 1, wherein the conduit has anaspect ratio defined as the cross-sectional width divided by thecross-sectional height, and the aspect ratio decreases along the lengthof the conduit from a proximal side to a distal side.
 15. A method ofseparating a high vapor pressure fluid from beef, comprising: (a) in anapparatus comprising a vessel, and a piston disposed within the vessel,wherein a space is provided adjacent to the piston, adding a high vaporpressure fluid with beef in the space; and (b) moving the piston tocompress the space to separate the fluid from the beef, wherein thefluid is compressed at a pressure to prevent evaporation and freezing ofthe beef.
 16. The method of claim 15, wherein the apparatus comprises asecond piston, wherein the pistons are disposed opposite to each other,and the pistons are moved together to compress the space to separate thefluid from the beef.
 17. The method of claim 15, wherein the high vaporpressure fluid does not exist as a liquid at 1 atmosphere and 20° C. 18.The method of claim 15, wherein the fluid is carbon dioxide.
 19. Themethod of claim 15, wherein the apparatus further comprises a spacebehind the piston, wherein the space adjacent to and behind the pistonare in communication, and the fluid is transferred behind the pistonduring compression.
 20. A method for producing a beef product having apredetermined fat content, comprising: (a) transferring a mixturethrough a conduit, wherein the mixture comprises lean particles, fatparticles, and a fluid; (b) transferring a first portion of the mixturehaving accumulated lean particles through a first conduit branchconnected to the conduit, wherein the portion of the mixture transferredin the first conduit branch has a majority of the lean particles in themixture; (c) transferring a second portion of the mixture havingaccumulated fat particles through a second conduit branch connected tothe conduit, wherein the portion of the mixture transferred in thesecond conduit branch has a majority of the fat particles in themixture; (d) measuring the first portion of the mixture having theaccumulated lean particles in the first conduit branch and determining acontent of fat in the first portion; (e) comparing the content of fat inthe first portion with a target fat content; and further performing (f1)or (f2): (f1) increasing the massflow of the second portion of themixture through the second conduit branch to decrease the fat content ofthe first portion of the mixture in the first conduit branch; or (f2)decreasing the massflow of the second portion of mixture through thesecond conduit branch to increase the fat content of the first portionof the mixture in the first conduit branch.